Smoking substitute consumable

ABSTRACT

The present disclosure relates to smoking substitute consumables, including an aerosol-forming article comprising an aerosol-forming substrate and a terminal filter element at a downstream axial end of the article/consumable. The terminal filter element may comprise a hollow bore extending from an upstream axial end of the terminal filter element to a downstream axial end of the terminal filter element. The hollow bore may be off-set from the axial centre of the terminal filter element.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to, and is a continuation application of, Patent Cooperation Treaty Patent Application Number PCT/EP2019/079134, titled “Smoking Substitute Consumable”, filed on Oct. 25, 2019, which claims priority to GB 1817537.2, filed on Oct. 29, 2018; Patent Cooperation Treaty Patent Application Number PCT/EP2019/079144, titled “Smoking Substitute Consumable”, filed on Oct. 25, 2019, which claims priority to GB 1817558.8, filed on Oct. 29, 2018; Patent Cooperation Treaty Patent Application Number PCT/EP2019/079151, titled “Smoking Substitute Consumable”, filed on Oct. 25, 2019, which claims priority to GB 1817585.1, filed on Oct. 29, 2018; Patent Cooperation Treaty Patent Application Number PCT/EP2019/079153, titled “Smoking Substitute Consumable”, filed on Oct. 25, 2019, which claims priority to GB 1817549.7, filed on Oct. 29, 2018; Patent Cooperation Treaty Patent Application Number PCT/EP2019/079168, titled “Smoking Substitute Consumable”, filed on Oct. 25, 2019, which claims priority to GB 1817542.2, filed on Oct. 29, 2018; Patent Cooperation Treaty Patent Application Number PCT/EP2019/079172, titled “Smoking Substitute Consumable”, filed on Oct. 25, 2019, which claims priority to GB 1817564.6, filed on Oct. 29, 2018; Patent Cooperation Treaty Patent Application Number PCT/EP2019/079173, titled “Smoking Substitute Consumable”, filed on Oct. 25, 2019, which claims priority to GB 1817541.4, filed on Oct. 29, 2018; Patent Cooperation Treaty Patent Application Number PCT/EP2019/079178, titled “Smoking Substitute Consumable”, filed on Oct. 25, 2019, which claims priority to GB 1817582.8, filed on Oct. 29, 2018; Patent Cooperation Treaty Patent Application Number PCT/EP2019/079190, titled “Smoking Substitute Consumable”, filed on Oct. 25, 2019, which claims priority to GB 1817583.6, filed on Oct. 29, 2018; Patent Cooperation Treaty Patent Application Number PCT/EP2019/079198, filed on Oct. 25, 2019, which claims priority to GB 1817536.4, filed on Oct. 29, 2018; Patent Cooperation Treaty Patent Application Number PCT/EP2019/079241, titled “Smoking Substitute Consumable”, filed on Oct. 25, 2019, which claims priority to GB 1817568.7, filed on Oct. 29, 2018; Patent Cooperation Treaty Patent Application Number PCT/EP2019/079248, titled “Smoking Substitute Consumable”, filed on Oct. 25, 2019, which claims priority to GB 1817569.5, filed on Oct. 29, 2018; Patent Cooperation Treaty Patent Application Number PCT/EP2019/079254, titled “Smoking Substitute Consumable”, filed on Oct. 25, 2019, which claims priority to GB 1817584.4, filed on Oct. 29, 2018; Patent Cooperation Treaty Patent Application Number PCT/EP2019/079269, titled “Smoking Substitute Consumable”, filed on Oct. 25, 2019, which claims priority to GB 1817566.1, filed on Oct. 29, 2018; Patent Cooperation Treaty Patent Application Number PCT/EP2019/079280, titled “Smoking Substitute Consumable”, filed on Oct. 25, 2019, which claims priority to GB 1817544.8, filed on Oct. 29, 2018; and Patent Cooperation Treaty Patent Application Number PCT/EP2019/079284, titled “Smoking Substitute Consumable”, filed on Oct. 25, 2019, which claims priority to GB 1817573.7, filed on Oct. 29, 2018; the entire contents of each of which are hereby incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates to a consumable for use in a smoking substitute system and particularly, although not exclusively, to a heat-not-burn (HNB) consumable.

BACKGROUND

The smoking of tobacco is generally considered to expose a smoker to potentially harmful substances. It is generally thought that a significant amount of the potentially harmful substances are generated through the heat caused by the burning and/or combustion of the tobacco and the constituents of the burnt tobacco in the tobacco smoke itself.

Conventional combustible smoking articles, such as cigarettes, typically comprise a cylindrical rod of tobacco comprising shreds of tobacco which is surrounded by a wrapper, and usually also a cylindrical filter axially aligned in an abutting relationship with the wrapped tobacco rod. The filter typically comprises a filtration material which is circumscribed by a plug wrap. The wrapped tobacco rod and the filter are joined together by a wrapped band of tipping paper that circumscribes the entire length of the filter and an adjacent portion of the wrapped tobacco rod. A conventional cigarette of this type is used by lighting the end opposite to the filter, and burning the tobacco rod. The smoker receives mainstream smoke into their mouth by drawing on the mouth end or filter end of the cigarette.

Combustion of organic material such as tobacco is known to produce tar and other potentially harmful by-products. There have been proposed various smoking substitute systems (or “substitute smoking systems”) in order to avoid the smoking of tobacco.

Such smoking substitute systems can form part of nicotine replacement therapies aimed at people who wish to stop smoking and overcome a dependence on nicotine.

Smoking substitute systems include electronic systems that permit a user to simulate the act of smoking by producing an aerosol (also referred to as a “vapour”) that is drawn into the lungs through the mouth (inhaled) and then exhaled. The inhaled aerosol typically bears nicotine and/or flavourings without, or with fewer of, the odour and health risks associated with traditional smoking.

In general, smoking substitute systems are intended to provide a substitute for the rituals of smoking, whilst providing the user with a similar experience and satisfaction to those experienced with traditional smoking and with combustible tobacco products. Some smoking substitute systems use smoking substitute articles that are designed to resemble a traditional cigarette and are cylindrical in form with a mouthpiece at one end.

The popularity and use of smoking substitute systems has grown rapidly in the past few years. Although originally marketed as an aid to assist habitual smokers wishing to quit tobacco smoking, consumers are increasingly viewing smoking substitute systems as desirable lifestyle accessories.

There are a number of different categories of smoking substitute systems, each utilising a different smoking substitute approach.

One approach for a smoking substitute system is the so-called “heat not burn” (“HNB”) approach in which tobacco (rather than an “e-liquid”) is heated or warmed to release vapour. The tobacco may be leaf tobacco or reconstituted tobacco. The vapour may contain nicotine and/or flavourings. In the HNB approach the intention is that the tobacco is heated but not burned, i.e., the tobacco does not undergo combustion.

A typical HNB smoking substitute system may include a device and a consumable. The consumable may include the tobacco material. The device and consumable may be configured to be physically coupled together. In use, heat may be imparted to the tobacco material by a heating element of the device, wherein airflow through the tobacco material causes moisture in the tobacco material to be released as vapour. A vapour may also be formed from a carrier/humectant in the tobacco material (this carrier may for example include propylene glycol and/or vegetable glycerine) and additionally volatile compounds released from the tobacco. The released vapour may be entrained in the airflow drawn through the tobacco.

As the vapour passes through the consumable (entrained in the airflow) from an inlet to a mouthpiece (outlet), the vapour cools and condenses to form an aerosol for inhalation by the user. The aerosol will normally contain the volatile compounds.

Known HNB consumables can often provide insufficient mixing of the vapour components, i.e., incomplete mixing of the nicotine with the PG/VG because they are vaporised from the tobacco at different temperatures. Unmixed nicotine gas can result in an unpleasant sensation for the user.

In HNB smoking substitute systems, heating as opposed to burning the tobacco material is believed to cause fewer, or smaller quantities, of the more harmful compounds ordinarily produced during smoking. Consequently, the HNB approach may reduce the odour and/or health risks that can arise through the burning, combustion and pyrolytic degradation of tobacco.

In some cases, the aerosol passing from the mouthpiece (i.e., being inhaled by a user) may not be in a desirable state. Thus, it may be desirable to alter one or more characteristics of the aerosol before it is inhaled by the user.

There is a need for improved design of HNB consumables to enhance the user experience and improve the function of the HNB smoking substitute system. One example of improved function is the improved mixing of the vapour components.

The present disclosure has been devised in the light of the above considerations.

SUMMARY OF THE DISCLOSURE First Mode of the Disclosure

At its most general, the first mode of the present disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable having a filter element with an axial bore off-set from the axial centre of the filter element.

According to a first aspect of the first mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and a terminal filter element at a downstream axial end of the article/consumable wherein the terminal filter element comprises a hollow bore extending from an upstream axial end of the terminal filter element to a downstream axial end of the terminal filter element wherein the hollow bore is off-set from the axial centre of the terminal filter element.

By providing an off-set hollow bore in the terminal filter element, the temperature of the vapour entering the user's mouth will be reduced whilst the visible vapour (total particulate matter) will be maintained. As the vapour/aerosol travels through the article/consumable, upon reaching the terminal filter element, it will meet the axial upstream end of the terminal filter element and will be forced to take a convoluted path through the off-set axial bore. This convoluted path will help mix and cool the vapour/aerosol prior to inhalation.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

The terminal filter element is provided at the downstream/mouth end of the article/consumable. The off-set bore extends the entire length of the terminal filter element and terminates at the downstream/mouth end of the article/consumable.

Preferably, the terminal filter element comprises only the single off-set bore and no other bores, i.e., the terminal filter element is preferably solid other than for the single off-set bore.

The term axially offset means that the axial centre of the bore is not aligned with the axial centre of the filter element. The axial centre of the filter element may, however, be within the off-set bore.

There may also be an upstream filter element provided upstream of the terminal filter element and downstream of the aerosol-forming substrate.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

The upstream filter element may be a solid filter element or may be a hollow bore filter element comprising an axial bore.

The or each filter element is formed of a smoke-permeable material. The terminal and/or upstream filter element(s) may be comprised of cellulose acetate or polypropylene tow. The terminal and/or upstream filter element(s) may be comprised of activated charcoal. The terminal and/or upstream filter element(s) may be comprised of paper. The terminal and/or upstream filter element(s) may each be circumscribed with a respective plug wrap, e.g., a paper plug wrap.

The porosity of the upstream filter element may be greater than the porosity of the terminal filter element.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m², e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators—the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g., wood fibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt %, e.g., between 6-9 wt % such as between 7-9 wt %.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including, e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be circumscribed by a wrapping layer, e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost). The upstream filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The terminal and/or upstream filter element(s) may each have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The terminal and/or upstream filter element(s) may each have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm. The diameter of the axial bore in the upstream filter element may be greater than the diameter of the offset bore in the terminal filter element.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The upstream and terminal filter elements may be adjacent one another or may be spaced apart.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and the upstream filter element and/or between the upstream and terminal filter elements. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximise heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may comprise a cardboard tube. The spacer element may be provided between the upstream and terminal filter elements. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the first mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the first mode and a device comprising a heating element.

The device may be a HNB device, i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated, e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the first mode, there is provided a method of using a smoking substitute system according to the second aspect of the first mode, the method comprising:

inserting the article/consumable into the device; and

heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

Second Mode of the Disclosure

At its most general, the second mode of the disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable having a flow restrictor element downstream of an aerosol-forming substrate.

According to a first aspect of the second mode, there is provided a Heat-Not-Burn (HNB) consumable comprising an aerosol-forming substrate and a flow restrictor element downstream of the aerosol-forming substrate.

In a second aspect of the second mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising, in axial flow arrangement, an aerosol-forming substrate, an upstream filter element, a spacer element and a terminal filter element, wherein at least one of the filter elements is a hollow bore filter element and wherein the article further comprises a flow restrictor element upstream of the terminal filter element and downstream of the aerosol-forming substrate.

By providing a flow restrictor element downstream of the aerosol-forming substrate, the various components of the vapour are forced to co-locate and thus mix as they pass through the flow restrictor element. This means that the user is not exposed to unmixed nicotine gas.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

The flow restrictor element may comprise a disc or rod having at least one axial perforation or channel. For example, the flow restrictor element may comprise a disc or rod having a single perforation or channel, e.g., at its axial centre. The or each perforation/channel may have a diameter of between 0.5 and 1.5 mm, e.g., around 1 mm.

During manufacture of the consumable/article, the size of the perforation(s)/channel(s) can be selected depending on the desired nicotine “hit” delivery.

The flow restrictor element may be formed of a vapour-impermeable material, e.g., it may be formed of a metallic foil (e.g., aluminium foil) or a plastic material. In other embodiments, the flow restrictor element may be formed of extruded tobacco or activated carbon.

The HNB consumable of the first aspect of the second mode preferably comprises in axial flow arrangement, an aerosol-forming substrate, an upstream filter element, a spacer element and a terminal filter element, wherein at least one of the filter elements is a hollow bore filter element and wherein the flow restrictor element is provided upstream of the terminal filter element and downstream of the aerosol-forming substrate.

In both the first and second aspect of the second mode, the flow restrictor element may be provided upstream of the spacer element. This allows expansion of the restricted vapour flow into the mixing chamber defined by the spacer element which further improves mixing of the vapour components. In some embodiments, the restrictor element is provided immediately upstream of the spacer element, i.e., interposed between the upstream filter element and the spacer element.

The aerosol-forming article of the second aspect of the second mode is preferably a heat-not-burn (HNB) consumable.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol, i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end. The term “axial flow direction” refers to a direction from the upstream end of the article/consumable to the downstream end.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m² e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators—the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g., wood fibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt %, e.g., between 6-9 wt % such as between 7-9 wt %.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including, e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be circumscribed by a wrapping layer, e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The HNB consumable of the first aspect of the second mode may comprise and the article of the second aspect of the second mode may comprise at upstream filter element and a terminal filter element. The upstream filter element is upstream of the terminal filter element (but downstream of the aerosol-forming substrate). The terminal filter element may be at the downstream/mouth end of the article/consumable.

One or both of the filter elements may be comprised of cellulose acetate or polypropylene tow. One or both of the filter elements may be comprised of activated charcoal. One or both of the filter elements may be comprised of paper. One or both filter elements may be circumscribed with a respective plug wrap, e.g., a paper plug wrap.

The filter elements may each have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of one or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

At least one of the filter elements is a hollow bore filter element. In some embodiments, both the filter elements are hollow bore filter elements. The or each hollow bore filter may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm. Where the upstream filter element is a hollow bore filter element, the bore diameter is preferably greater than the diameter of the flow restrictor perforation, i.e., preferably greater than 1.5 mm.

The upstream filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding the adjacent upstream element, e.g., the adjacent upstream spacer element.

In embodiments where only one of the filter elements is a hollow bore filter element, the other (solid) filter element may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavourant, e.g., any of the flavourants listed above. The capsule can be crushed by the user during smoking of the article/consumable to release the flavourant. The capsule may be located at the axial centre of the (solid) filter element.

The spacer element defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may comprise a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm

In some embodiments, the article/consumable may further comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and the upstream filter element or between two filter elements. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximise heat exchange and cooling of the aerosol.

In a third aspect of the second mode, there is provided a smoking substitute system comprising a HNB consumable according to the first aspect of the second mode or an aerosol-forming article according to the second aspect of the second mode and a device comprising a heating element.

The device may be a HNB device, i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated, e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a fourth aspect of the second mode, there is provided a method of using a smoking substitute system according to the second aspect of the second mode, the method comprising:

inserting the article/consumable into the device; and

heating the article/consumable using the heating element.

Third Mode of the Disclosure

At its most general, the third mode of the disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable comprising a phase change material.

According to a first aspect of the third mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising cooling element comprising a phase change material.

The phase change material may be capable of storing and releasing energy during phase changes. The phase change material may be a solid-liquid phase change material, whereby when the phase change material is heated, it melts from a solid to a liquid and stores the thermal energy. Heat may be transferred from vapour (passing through the cooling element) to the phase change material of the cooling element. This transfer of heat may result in cooling of the vapour, which may facilitate condensation of the vapour so as to form an aerosol. During phase change, the phase change material remains at a generally consistent temperature, which may allow a large amount of heat to be transferred (due to a temperature differential between the vapour and the phase change material) from the vapour to the phase change material. Thus, a cooling element comprising phase change material may, in some cases, provide increased cooling of vapour passing through it.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

In some embodiments, the phase change material may be an organic phase change material. The phase change material may, for example, be paraffin (CnH2n+2) based, e.g., paraffin with 14 to 34 carbons e.g., 20 carbons (icosane/eicosane).

In some embodiments, the phase change material may have a melting point of between 20° C. and 40° C. or, e.g., between 25° C. and 35° C., or between 25° C. and 31° C. Thus, the phase change material may have a melting point at a temperature that is close to room temperature, such that heat from vapour (that may be hotter than room temperature) passing across the cooling element is transferred to the phase change material (which stores the heat as latent heat during the phase change).

In some embodiments the cooling element may comprise a plurality of phase change beads. The phase change beads may comprise the phase change material.

In some embodiments each phase change bead may comprise a shell enclosing a core formed of the phase change material. The shell may be formed of glass or plastics material. Each phase change bead may be substantially spherical.

The cooling element may comprise a body, e.g., a cylindrical body and the phase change material/beads may be dispersed within the body. The distribution of the phase change material/beads in the body may be a substantially even distribution, or the phase change material/beads may be localised to particular regions of the body. For example, there may be a concentration of phase change material/beads in regions of the body that are hotter during use of the aerosol-forming article.

The cylindrical body may have an axial bore extending therethrough and the phase change material/beads may be localised proximal the bore.

The cylindrical body may comprise a matrix of fibrous, granular, sheet or solid plastics material.

The plastics material may comprise one or more of viscose, cellulose, polyester, polyacrylonitrile, polylactic acid, polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), and polyethylene terephtha late (PET).

In some embodiments, the fibrous plastics material may be selected from viscose, cellulose, polyester, acrylic or polylactic acid fibres.

The fibres of the fibrous material may be randomly oriented within the cylindrical body. Alternatively, the fibres of the fibrous material may be oriented in the same direction (e.g., the longitudinal direction) within the cylindrical body.

In some embodiments the fibrous material may be in the form of a fibrous sheet. The sheet may be folded (or, e.g., crimped, rolled, etc.) so as to form the substantially cylindrical body. When folded, crimped and/or rolled, the sheet may define a plurality of channels extending through the cooling element. The sheet may be sprayed or coated with the phase change material prior to folding/crimping or rolling so that the phase change material is dispersed within the resulting cylindrical body.

The cooling element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In some embodiments the aerosol-forming article comprises an aerosol-forming substrate, the cooling element located downstream of the aerosol-forming substrate.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol, i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m², e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives (i.e., in addition to the phase change material) selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators—the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g., wood fibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt %, e.g., between 6-9 wt % such as between 7-9 wt %.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including, e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be at least partly circumscribed by a wrapping layer, e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The article/consumable may comprise at least one filter element. There may be a terminal filter element at the downstream/mouth end of the article/consumable. The cooling element may be located between the terminal filter and the aerosol-forming substrate. There may be an upstream filter element (upstream of the downstream axial end). The cooling element may be located between the upstream filter element and the terminal filter element.

There may be a plurality of, e.g., two filter elements which may be adjacent one another or which may be spaced apart. Any filter element(s) upstream of the terminal filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer. Similarly, the cooling element may be at least partly (e.g., entirely) circumscribed by the wrapping layer.

The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be comprised of cellulose acetate or polypropylene tow. The at least one filter element (e.g., the terminal filter element/upstream filter element) may be comprised of activated charcoal. The at least one filter element (e.g., the terminal element/upstream filter element) may be comprised of paper. The at least one filter element (e.g., the terminal element/upstream filter element) may be comprised of plant material, e.g., extruded plant material. The or each filter element may be circumscribed with a plug wrap, e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be a solid filter element. The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be a hollow bore filter element. The or each hollow bore filter element may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable (e.g., the cooling element) by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The or at least one of the filter elements, e.g., the terminal filter element may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavourant, e.g., any of the flavourants listed above. The capsule can be crushed by the user during smoking of the article/consumable to release the flavourant. The capsule may be located at the axial centre of the filter element.

The article/consumable may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable. For example, it may be provided between the aerosol-forming substrate and the upstream filter element and/or between one of the two filter elements and the cooling element. The spacer acts to allow both cooling (e.g., in addition to the cooling element) and mixing of the aerosol. The spacer element may be a tubular spacer element, e.g., it may comprise a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the third mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the third mode and a device comprising a heating element.

The device may be a HNB device, i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated, e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the third mode, there is provided a method of using a smoking substitute system according to the second aspect of the third mode, the method comprising inserting the article/consumable into the device, and heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

Fourth Mode of the Disclosure

At its most general, the fourth mode of the present disclosure relates to an aerosol-forming article e.g., a smoking substitute article such as an HNB consumable having a hollow bore filter at its axial downstream end.

According to a first aspect of the fourth mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising: an aerosol-forming substrate wherein the article further comprises a terminal filter element at the axial downstream of end of the article, the terminal filter element being a hollow bore filter element; and one or more of an upstream filter element, an upstream aerosol-cooling element and an upstream spacer element.

The terminal filter element allows delivery of an aerosol (through the hollow bore) to the user's mouth that remains rich in volatile compound and visible vapour. The terminal hollow bore filter also reduces the resistance to draw (RTD) which provides a more comfortable smoking experience for the user. Furthermore, the terminal hollow bore filter acts as an airflow restrictor which contributes to a vapour mixing effect by increasing the local airflow speed within the bore.

Where present, the upstream filter element (i.e., upstream from the terminal filter element but downstream from the aerosol-forming substrate) acts to filter particulate matter from the vapour/aerosol generated during heating of the aerosol-forming substrate. Where present, the upstream cooling element acts to cool the vapour prior to user inhalation thus increasing comfort for the user. Where present the spacer element acts to cool and mix the vapour generated from the aerosol-forming substrate.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol, i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

The internal diameter of the bore in the terminal filter element may be between 1 and 3 mm. For example, the internal dimeter of the bore may be substantially about 1 mm or 2 mm or 3 mm.

The upstream filter element may also be a hollow bore filter element which will further increase the volatile compound concentration in the aerosol, further reduce the resistance to draw and further increase vapour mixing.

The internal diameter of the bore in the upstream filter element may be greater than the internal diameter of the bore in the terminal filter element. For example, the internal dimeter of the bore may be substantially about 2 mm or 3 mm or 4 mm, i.e., between 2 and 4 mm.

In some examples, the internal bore diameter of the upstream filter element is around 3 mm and the internal diameter of the terminal filter element is around 2 mm.

The upstream and/or terminal filter element may be comprised of cellulose acetate or polypropylene tow. The upstream and/or terminal filter element may be comprised of activated charcoal. The upstream and/or terminal filter element may be comprised of paper.

In some embodiments, the density of the material forming the terminal filter element is increased, e.g., is greater than the density of the material forming the upstream filter element in order to force the air flow through the bore in the terminal filter element. The terminal bore filter may be formed of substantially solid/non-porous material.

The or each filter element may be circumscribed with a plug wrap, e.g., a paper plug wrap.

In some embodiments, the upstream filter element and terminal filter element may be axially spaced for example, the upstream filter element and the terminal filter element may be spaced by the cooling element and/or the spacer element.

The aerosol-cooling element is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user. The aerosol-cooling element may be axially adjacent the terminal filter element. The aerosol-cooling element may be axially adjacent the upstream filter element.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximise heat exchange and cooling of the aerosol.

The spacer element that defines a space or cavity or chamber, for example, a space or cavity between the two filters. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may be axially adjacent the terminal filter element. The spacer element may be axially adjacent the upstream filter element.

The spacer element may be a tubular element, e.g., a cardboard tube.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

The article/consumable comprises an aerosol-forming substrate which is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m², e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators—the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g., wood fibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt %, e.g., between 6-9 wt % such as between 7-9 wt %.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including, e.g., citrus, cherry, etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be circumscribed by a wrapping layer, e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The upstream and/or terminal filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The upstream filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer. The aerosol-cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable (e.g., to the cooling element or spacer) by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element (e.g., the cooling element or spacer).

In a second aspect of the fourth mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the fourth mode and a device comprising a heating element.

The device may be a HNB device, i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated, e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the fourth mode, there is provided a method of using a smoking substitute system according to the second aspect of the fourth mode, the method comprising:

inserting the article/consumable into the device; and

heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

Fifth Mode of the Present Disclosure

At its most general, the fifth mode of the present disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable comprising a cavity in an aerosol-forming material, the cavity housing a vapour modifier for modifying the vapour released during heating of the aerosol-forming material.

According to a first aspect of the fifth mode, the present disclosure provides an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate wherein the aerosol-forming substrate comprises a first, upstream portion of aerosol-forming material and a second, downstream portion of aerosol-forming material wherein the first and second portions of aerosol-forming material are axially spaced by a cavity housing a vapour modifier.

By providing an aerosol-forming substrate having a vapour modifier within a cavity spacing first and second portions of an aerosol-forming material, the user experience can be tailored and thereby enhanced. The vapour modifier can be selected such that the user is exposed to a vapour/an aerosol having different properties, e.g., a modified flavour and/or modified strength of volatile compounds and/or modified visible vapour volume.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

The term “vapour modifier” is intended to refer to a component, e.g., a material, compound or substrate that modifies the vapour generated by the aerosol-forming substrate, e.g., that modifies the flavour of and/or the strength of volatile compound in and/or the visible vapour (total particulate matter TPM) of the vapour generated by the aerosol-forming substrate.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol, i.e., with the downstream end of the consumable being the mouth end or outlet where the aerosol exits the consumable for inhalation by the user. The upstream end of the consumable is the opposing end to the downstream end.

In some embodiments, the first, upstream portion of aerosol-forming material and the second, downstream portion of aerosol-forming material are both formed of the same aerosol-forming material, i.e., are both formed from a first aerosol-forming material. In other words, the cavity and vapour modifier are sandwiched between two portions of the first aerosol-forming material.

In some embodiments, the vapour modifier may be a second aerosol-forming material. The second aerosol-forming material is different to aerosol-forming material used to form the first and second portions of the aerosol-forming substrate, e.g., the second aerosol-forming material is different to the first aerosol-forming material.

In these embodiments, there is provided an article/HNB consumable comprising an aerosol-forming substrate wherein the aerosol-forming substrate comprises two portions of a first aerosol-forming material sandwiching an axially interposed portion of a second aerosol-forming material.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the consumable.

In order to generate an aerosol, the first and second (where present) aerosol-forming material comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The first and/or second aerosol-forming material may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

In preferred embodiments, both the first aerosol-forming material and the second aerosol-forming material comprises tobacco which will contain nicotine as a volatile compound.

Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The aerosol-forming material forming the upstream and downstream portions (e.g., the first aerosol-forming material) may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming material forming the upstream and downstream portions (e.g., the first aerosol-forming material) may comprise may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the first aerosol-forming material has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m², e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The first aerosol-forming material may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The second aerosol-forming material may comprise a different one (relative to the first aerosol-forming material) of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon). The second aerosol-forming material may comprise extruded tobacco. For example, the second aerosol-forming material may comprise pellets, granules or chips of extruded tobacco.

Extruded tobacco can produced by forming a liquid mixture of powered tobacco and a binding agent such as a gum (e.g., xanthan, guar, arabic and/or locust bean gum). The liquid mixture is heated and then extruded through a die. The extrudate is dried and then may be subsequently cut into pellets, chips or granules.

In some embodiments, the first and second portions of the aerosol-forming substrate both comprise reconstituted tobacco (e.g., shreds/strip of a sheet of recon tobacco) and the second aerosol-forming material (housed within the cavity) comprises extruded tobacco (e.g., pellet/chips/granules of extruded tobacco). The extruded tobacco housed in the cavity will deliver a vapour with a higher nicotine content than the reconstituted tobacco portions.

In other embodiments, the vapour modifier is an additive carrier. In these embodiments, the aerosol-forming material forming the first and second portions of the aerosol-forming substrate (e.g., the first aerosol-forming material may be as described above). In some embodiments, there is provided an article/HNB consumable comprising an aerosol-forming substrate wherein the aerosol-forming substrate comprises two portions of an aerosol-forming material sandwiching an additive carrier.

The additive carrier may a capsule or micro-moulding, e.g., a crushable or meltable capsule or micro-moulding having a crushable or meltable outer shell containing the additive. The additive carrier may be substantially spherical.

The additive carrier may include an additive selected from humectants or flavourants.

Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). Inclusion of an humectant in the additive carrier within the cavity allows the generation of an increased amount of visible vapour potentially at lower temperatures.

The flavourant may be provided in solid or liquid form within the additive carrier. It may include menthol, liquorice, chocolate, fruit flavour (including, e.g., citrus, cherry, etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour.

The aerosol-forming substrate, e.g., the first and/or second aerosol-forming material may further comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators—the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g., wood fibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt %, e.g., between 6-9 wt % such as between 7-9 wt %.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including, e.g., citrus, cherry, etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed/dosed throughout the first and/or second aerosol-forming material.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm.

Each of the first/second portions of aerosol-forming material may have an axial length of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 9 mm such as around 7 mm.

The cavity may have an axial length of around 3 to 7 mm, e.g., 4 or 5 to 6 mm such as around 6 mm.

The aerosol-forming substrate may be circumscribed by a wrapping layer, e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The article/consumable may comprise at least one filter element. There may be a terminal filter element at the downstream/mouth end of the article/consumable.

The or at least one of the filter element(s) (e.g., the terminal filter element) may be comprised of cellulose acetate or polypropylene tow. The at least one filter element (e.g., the terminal filter element) may be comprised of activated charcoal. The at least one filter element (e.g., the terminal element) may be comprised of paper. The or each filter element may be at least partly (e.g., entirely) circumscribed with a plug wrap, e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The or at least one of the filter element(s) may be a solid filter element. The or at least one of the filter element(s) may be a hollow bore filter element. The or each hollow bore filter may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

There may be a plurality of, e.g., two filter elements which may be adjacent one another or which may be spaced apart. Any filter element(s) upstream of the terminal filter element may be circumscribed by the (paper) wrapping layer.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The or at least one of the filter elements, e.g., the terminal filter element may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavourant, e.g., a liquid flavourant as described above. The capsule can be crushed by the user during smoking of the consumable to release the flavourant. The capsule may be located at the axial centre of the terminal filter element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and a/the filter element and/or between two filter elements. The aerosol cooling element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximise heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity between the aerosol-forming substrate and the downstream end of the consumable. The spacer element may comprise a cardboard tube. The spacer element may be circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the fifth mode, there is provided a system comprising an article/consumable according to the first aspect of the fifth mode and a device comprising a heating element.

The device may be a HNB device, i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated, e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the fifth mode, there is provided a method of using a system according to the second aspect of the fifth mode, the method comprising:

inserting the article/consumable into the device; and heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

Sixth Mode of the Present Disclosure

At its most general, the sixth mode of the present disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable comprising a filter having a non-circular bore.

According to a first aspect of the sixth mode, there is provided a filter element for an aerosol-forming article, the filter element comprising a bundle of filter tows with a bore extending longitudinally therethrough, at least a portion of the bore having a non-circular transverse cross-section.

The presence of a bore in the filter element may act to mix volatile compounds (e.g., nicotine) with outer components (e.g., humectant) of a vapour/aerosol passing through the filter element. The bore may also result in a more reactive draw when used in a smoking substitute system (as discussed below). A non-circular transverse cross-section may result in the aerosol/vapour flowing through the bore having a different flow characteristic or flow pattern than if the cross-section of the bore were circular.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

The filter tows may be, e.g., acetate tows or polypropylene tows.

In some embodiments, the bore in the filter element has a non-circular transverse cross-section along its entire axial length.

In some embodiments the transverse cross-section of the at least a portion of the bore may comprise a plurality of edges.

At least one of the plurality of edges may be substantially straight (e.g., linear). For example, the bore may have a square or rectangular or triangular, or pentagonal or hexagonal or octagonal etc. transverse cross-sectional profile.

In other embodiments, the edges may be curved. For example, the bore may have a heart-shaped transverse cross-sectional profile.

In some embodiments the transverse cross-section of the at least a portion of the bore may comprise a central portion and a plurality of lobes projecting outwardly from the central portion. The lobes may each comprise a generally linear form (e.g., formed of a plurality of straight edges), or may comprise a curved form (e.g., formed of one or more curved edges).

In some embodiments the shape of the transverse cross-section of the at least a portion of the bore may be one of a star shape, flower shape or asterisk shape (e.g., five-pointed or six-pointed).

In some embodiments the cross-sectional area of the transverse cross-section of the bore may be substantially consistent/uniform for the entire axial length, or substantially the entire axial length, of the bore. Alternatively, the cross-sectional area of the transverse cross-section of the bore may vary along the length of the bore. For example, the bore may have a larger cross-section at a first axial (e.g., upstream) end than at an opposing second axial (e.g., downstream) end (and may gradually decrease from the first end to the second end).

In some embodiments the shape of the transverse cross-section of the bore may be substantially consistent/uniform for the entire axial length, or substantially the entire axial length, of the bore (i.e., such that the entire bore has a non-circular transverse cross-section). Alternatively, the shape of the cross-section of the bore may vary along the length of the bore. For example, the bore may have a square cross-section at a first end and a triangular cross-section at an opposing second end (and may gradually change from being a square to a triangle from the first end to the second end).

The bore may extend completely through the filter element. Alternatively, the bore may extend partway through the filter element. The bore may extend along a central longitudinal axis of the filter element or may be offset (i.e., in a radial direction) from the central longitudinal axis. The bore may extend at an angle to a longitudinal axis of the filter element. The bore may alternatively extend along a curved path (i.e., rather than a linear path along an axis).

The cross-sectional area of the at least a portion of the bore may be between 0.8 mm² and 20 mm², e.g., between 3 mm² and 12 mm² or between 3 mm² and 7 mm².

In some embodiments the filter element may comprise a plurality of bores. Each of the plurality of bores may have a non-circular transverse cross-section. Each bore may be as described above. Each of the plurality of bores may comprise a transverse cross-section that is different to the transverse cross-section of one or more of the other bores. The non-circular cross-sections of the plurality of bores may have a total cross-sectional area of between 0.8 mm² and 20 mm², e.g., between 3 mm² and 12 mm² or between 3 mm² and 7 mm².

The filter element may have a substantially cylindrical shape. The axial length of the filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

According to a second aspect of the sixth mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate, and a filter element according to the first aspect of the sixth mode downstream of the aerosol-forming substrate.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol, i.e., with the downstream end of the article being the mouth end or outlet where the aerosol exits the article for inhalation by the user. The upstream end of the article is the opposing end to the downstream end.

In some embodiments the filter element may be a terminal filter element located at a downstream end of the aerosol-forming article. The or each bore may have a non-circular transverse cross-section at least at the downstream axial end of the terminal filter element.

In other embodiments the filter element may be an upstream filter element located proximate to the substrate.

In some embodiments the aerosol-forming article may be a heat-not-burn (HNB) consumable.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m², e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators—the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g., wood fibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt %, e.g., between 6-9 wt % such as between 7-9 wt %.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including, e.g., citrus, cherry, etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be circumscribed by a wrapping layer, e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The article/consumable may comprise one or more further filter elements in addition to the filter element described above (i.e., having one or more non-circular bores). Where the filter element is a terminal filter element, the further filter element may be an upstream filter element located between the substrate and the filter element (e.g., located adjacent or proximate to the substrate). Similarly, where the filter element is an upstream filter element, there may be a further filter element in the form of a terminal filter element located at a downstream end of the article.

The further filter element(s) (e.g., the upstream filter element) may be comprised of cellulose acetate or polypropylene tow. The at least one further filter element (e.g., the upstream filter element) may be comprised of activated charcoal. The at least one further filter element (e.g., the upstream filter element) may be comprised of paper. The at least one further filter element (e.g., the upstream filter element) may be comprised of extruded plant material. The or each filter element (i.e., including the filter element with the non-circular bore) may be circumscribed with a plug wrap, e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each further filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The or at least one of the further filter element(s) may be a solid filter element. The or at least one of the further filter element(s) may be a hollow bore filter element. The or each hollow bore filter element may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

There may be a plurality of, e.g., two filter elements which may be adjacent one another or which may be spaced apart. Any filter element(s) upstream of the terminal filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The or at least one of the further filter elements may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavourant, e.g., any of the flavourants listed above. The capsule can be crushed by the user during smoking of the article/consumable to release the flavourant. The capsule may be located at the axial centre of the further filter element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and the upstream filter element and/or between the two filter elements. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal bores to maximise heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable. For example, it may be between the aerosol-forming substrate and the upstream filter element and/or between the two filter elements. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may comprise a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a third aspect of the sixth mode, there is provided a system (e.g., a smoking substitute system) comprising an aerosol-forming article according to the first aspect of the sixth mode and a device comprising a heating element.

The device may be a HNB device, i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated, e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a fourth aspect of the sixth mode, there is provided a method of using a smoking substitute system according to the second aspect of the sixth mode, the method comprising inserting the article/consumable into the device, and heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

Seventh Mode of the Disclosure

At its most general, the seventh mode of the present disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable comprising two different forms of aerosol-forming material.

According to a first aspect of the seventh mode, the present disclosure provides an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate wherein the aerosol-forming substrate comprises at least a first aerosol-forming material and a second aerosol forming material wherein the first and second aerosol-forming materials are axially and/or radially segregated within the aerosol-forming substrate.

By providing an aerosol-forming substrate having at least two different aerosol-forming materials that are axially and/or segregated, the user experience can be tailored and thereby enhanced. During the smoking of a single consumable the user is exposed to a mix of vapours/aerosols having different properties, e.g., different flavours and/or different strengths of volatile compounds and/or different vapour volumes.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol, i.e., with the downstream end of the consumable being the mouth end or outlet where the aerosol exits the consumable for inhalation by the user. The upstream end of the consumable is the opposing end to the downstream end.

In embodiments where the aerosol-forming materials are axially segregated, the aerosol-forming substrate preferably comprises at least a first rod- or tube-shaped portion (formed of the first aerosol-forming material) and a second rod- or tube-shaped portion (formed of the second aerosol-forming material).

The first and second rod/tube portions may be axially adjacent one another or they may be axially spaced.

In embodiments where the aerosol-forming materials are radially segregated, the aerosol-forming substrate preferably comprises at least a first, radially outer rod- or tube-shaped portion (formed of the first aerosol-forming material) and a second, radially inner tube-shaped portion (formed of the second aerosol-forming material). In these embodiments, the first and second aerosol-forming materials are concentrically segregated within the aerosol-forming substrate.

The first and second rod/tube portions may be radially adjacent one another or they may be radially spaced.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the consumable.

In order to generate an aerosol, the first and second aerosol-forming materials comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The first and/or second aerosol-forming material may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

In preferred embodiments, both the first aerosol-forming material and the second aerosol-forming material comprises tobacco which will contain nicotine as a volatile compound. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The first aerosol-forming material may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The second aerosol-forming material comprises a different one (relative to the first aerosol-forming material) of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

One of the first or second aerosol-forming materials may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m², e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

In preferred embodiments, one of the first and second aerosol-forming materials comprises extruded tobacco.

The extruded tobacco may be in the form of a rod- or tube-shaped extrudate or the extruded tobacco may be in the form of chips/granules/pellets (which are subsequently formed into a rod/tube).

Extruded tobacco can produced by forming a liquid mixture of powered tobacco and a binding agent such as a gum (e.g., xanthan, guar, arabic and/or locust bean gum). The liquid mixture is heated and then extruded through a die (e.g., into the rod-/tube-shaped portion). The extrudate is dried. To form pellets, chips or granules of extruded tobacco, the dried extrudate is cut.

In some embodiments, one of the first and second aerosol-forming materials comprises reconstituted tobacco and the other comprises extruded tobacco (e.g., pellet/chips/granules of extruded tobacco or a rod/tube extrudate). The extruded tobacco will deliver a vapour with a higher nicotine content than the reconstituted tobacco.

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate, e.g., the first and/or second aerosol-forming material may further comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators—the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g., wood fibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt % e.g., between 6-9 wt % such as between 7-9 wt %.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed/dosed throughout the first and/or second aerosol-forming material.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm.

Each of the rod/rube portions in embodiments where the aerosol-forming materials are axially spaced may have an axial length of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 9 mm such as around 7 mm.

Each of the rod/rube portions in embodiments where the aerosol-forming materials are radially spaced may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm or such as around 12 or 13 mm.

The aerosol-forming substrate may be circumscribed by a wrapping layer e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The article/consumable may comprise at least one filter element. There may be a terminal filter element at the downstream/mouth end of the article/consumable.

The or at least one of the filter element(s) (e.g., the terminal filter element) may be comprised of cellulose acetate or polypropylene tow. The at least one filter element (e.g., the terminal filter element) may be comprised of activated charcoal. The at least one filter element (e.g., the terminal element) may be comprised of paper. The or each filter element may be at least partly (e.g., entirely) circumscribed with a plug wrap e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The or at least one of the filter element(s) may be a solid filter element. The or at least one of the filter element(s) may be a hollow bore filter element. The or each hollow bore filter may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

There may be a plurality of, e.g., two filter elements which may be adjacent one another or which may be spaced apart. Any filter element(s) upstream of the terminal filter element may be circumscribed by the (paper) wrapping layer.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The or at least one of the filter elements, e.g., the terminal filter element may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavourant, e.g., a liquid flavourant as described above. The capsule can be crushed by the user during smoking of the consumable to release the flavourant. The capsule may be located at the axial centre of the terminal filter element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and a/the filter element and/or between two filter elements. The aerosol cooling element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximise heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity between the aerosol-forming substrate and the downstream end of the consumable. The spacer element may comprise a cardboard tube. The spacer element may be circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the seventh mode, the present disclosure relates an aerosol-forming article (e.g., an HNB consumable) comprising an aerosol-forming substrate wherein the aerosol-forming substrate comprises at least a first aerosol-forming material and a second aerosol forming material wherein one of the first and second aerosol-forming materials is extruded tobacco.

For this aspect, the article, aerosol-forming substrate, first aerosol-forming material and second aerosol-forming material may be as described above for the first aspect of the seventh mode.

In a third aspect of the seventh mode, there is provided a system comprising an article/consumable according to the first or second aspects of the seventh mode and a device comprising a heating element.

The device may be a HNB device, i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated, e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a fourth aspect of the seventh mode, there is provided a system comprising an article/consumable according to the first aspects of the seventh mode and a device comprising a first heating element for heating the first aerosol-forming material within the substrate and a second heating element for heating the second aerosol forming material.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating elements.

Where the first and second materials are axially spaced in the article/consumable, the first and second heating elements may be axially spaced, e.g., they may each be a tubular heating element surrounding axially spaced portions of a cavity within the main body into which the article/consumable is received.

Where the first and second materials are radially spaced in the article/consumable, the first and second heating elements may be radially spaced, e.g., they may each be an elongated, e.g., rod, tube-shaped or blade heating element projecting into radially spaced portions of a cavity within the main body into which the article/consumable is received.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating elements. It may further comprise a control unit to control the supply of power to the heating elements.

In some embodiments, the heating elements are separable controllable to heat the first and second materials at different rates/temperatures. In these embodiments, the device (e.g., the main body) may comprise a first control unit for controlling heating of the first heating element and a second control unit for controlling heating of the second heating element.

In a fifth aspect of the seventh mode, there is provided a method of using a system according to the third or fourth aspects of the seventh mode, the method comprising:

inserting the article/consumable into the device; and

heating the article/consumable using the heating element(s).

In some embodiments (e.g., where the first and second aerosol-forming materials are radially spaced), the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element(s) upon insertion of the article/consumable. For example, the heating element(s) may penetrate the aerosol-forming substrate in the article/consumable.

Eighth Mode of the Disclosure

At its most general, the eighth mode of the present disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable comprising a terminal filter element comprising an upstream filter portion and a downstream filter portion.

According to a first aspect of the eighth mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and a terminal filter element, wherein the terminal filter element comprises an upstream filter portion and an axially adjacent downstream filter portion, and wherein one of the upstream and downstream filter portions is a hollow bore filter element and the other is a solid filter element.

The terminal filter element may provide good mixing of vapour/aerosol passing through the filter element (i.e., in the bore of the hollow bore filter element) whilst also ensuring the vapour/aerosol is adequately filtered (i.e., in the solid filter element).

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

In some embodiments the upstream filter portion may be the hollow bore filter element and the downstream filter portion may be the solid filter element. Alternatively, the upstream filter portion may be the solid filter element and the downstream filter portion may be the hollow bore filter element.

The term “sold filter element” is intended to refer to a filter element that does not have an axial bore. For example, where the terminal filter element is a cylindrical shape, the hollow bore filter element will have an annular transverse cross-section and the solid filter element will have a circular transverse cross-section. A solid filter element will, of course, be porous (to render it smoke-permeable) and may have numerous axial flow passages therethrough.

The axial bore of the hollow bore filter portion may have a diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

The upstream filter portion and downstream filter portion may be formed of the same or different material.

At least one of the terminal filter element portions (e.g., the upstream portion and/or downstream portion) may be comprised of cellulose acetate or polypropylene tow. At least one of the terminal filter element portions (e.g., the upstream portion and/or downstream portion) may be comprised of activated charcoal. At least one of the terminal filter element portions (e.g., the upstream portion and/or downstream portion) may be comprised of paper. At least one of the terminal filter element portions (e.g., the upstream portion and/or downstream portion) may be comprised of plant material, e.g., extruded plant material.

In some embodiments the terminal filter element may have a length (i.e., an axial extension) of between 8 mm and 16 mm, or e.g., between 10 mm and 14 mm, or e.g., between 11 mm and 13 mm, e.g., around 12 mm. The terminal filter element may have a length that is a standard length used in standard combining machines (i.e., for forming aerosol-forming articles such as e.g., heat-not-burn consumables). In this respect, the joining of the upstream and downstream filter portions may enable the terminal filter element to be processed with standard equipment.

In some embodiments the terminal filter element may have a substantially cylindrical shape. The terminal filter element (and each of the downstream and upstream filter portions) may have a diameter of between 5 mm and 10 mm, e.g., between 6 mm and 9 mm or 6 mm and 8 mm, e.g., around 7 mm.

In some embodiments the upstream filter portion may have substantially the same length as the downstream filter portion. Alternatively, the upstream filter portion may be longer than the downstream filter portion or the upstream filter portion may be shorter than the downstream filter portion.

The length of the upstream filter portion may be between 4 mm and 8 mm, or e.g., between 5 mm and 7 mm, or e.g., around 6 mm. The length of the downstream filter portion may be between 4 mm and 8 mm, or e.g., between 5 mm and 7 mm, or e.g., around 6 mm.

In some embodiments the upstream filter portion may be joined to the downstream filter portion (i.e., the filter portions may not be integrally formed, but joined by some further means). The upstream filter portion and downstream portion may be at least partially circumscribed by a joining layer. The joining layer may be in the form of a plug wrap. The plug wrap may be a paper plug wrap. The upstream filter portion and the downstream filter portion may be entirely circumscribed by the plug wrap.

In some embodiments the terminal filter element may comprise an additive. The additive may be a flavourant. The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate. For example, the flavourant (or additive) may be isolated to the upstream filter portion, or instead may be isolated to the downstream filter portion. Alternatively, both the upstream and downstream filter portions may comprise the additive (e.g., flavourant). The additive may be sprayed, painted or coated onto the filter element or filter portion. The filter element or filter portion may be impregnated with the additive.

The additive may be in the form of a capsule located in the solid filter portion. The capsule may be e.g., a crushable capsule (crush-ball) containing a liquid flavourant, e.g., any of the flavourants listed above. The capsule can be crushed by the user during smoking of the article to release the flavourant. The capsule may be located at the axial centre of the (upstream or downstream) portion of the solid filter portion.

The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable (i.e., upstream of the terminal filter).

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m², e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators—the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g., wood fibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt % e.g., between 6-9 wt % such as between 7-9 wt %.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be at least partly circumscribed by a wrapping layer e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The article/consumable may comprise an upstream filter element (upstream of the terminal filter element at the downstream axial end). The upstream filter element may be between the upstream filter portion of the terminal filter element and the aerosol-forming substrate. The upstream filter portion may be axially adjacent to the aerosol-forming substrate.

There may be further filter elements (i.e., in addition to the upstream and terminal filter elements). The filter elements may be adjacent one another or which may be spaced apart. Any filter element(s) upstream of the terminal filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The upstream filter element or further filter elements may be comprised of cellulose acetate or polypropylene tow. The upstream filter element or further filter elements may be comprised of activated charcoal. The upstream filter element or further filter elements may be comprised of paper. The upstream filter element or further filter elements may be comprised of plant material, e.g., extruded plant material. The upstream filter element or further filter elements may be circumscribed with a plug wrap e.g., a paper plug wrap.

The upstream filter element or further filter elements may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of each of the upstream filter element or further filter elements may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

Each of the upstream filter element or further filter elements may be a solid filter element. Each of the upstream filter element or further filter elements may be a hollow bore filter element. The or each hollow bore filter element may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 3 and 4 mm, e.g., around 3.5 mm.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The upstream filter element or any further filter elements may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavourant, e.g., any of the flavourants listed above. The capsule can be crushed by the user during smoking of the article/consumable to release the flavourant. The capsule may be located at the axial centre of the respective filter element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and the upstream filter element and/or between the upstream filter element and the terminal filter element. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximise heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable. For example, it may be provided between the aerosol-forming substrate and the upstream filter element and/or between the upstream filter element and the terminal filter element. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may be a tubular spacer element e.g., it may comprise a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the eighth mode there is provided a method for forming an aerosol-forming article, the method comprising joining a first filter portion to a second filter portion to form a terminal filter element, and combining the terminal filter element with an aerosol-forming substrate to form the aerosol-forming article.

In some embodiments the first filter portion is a hollow bore filter element and the second filter portion is a solid filter element.

In some embodiments the first and second filter portions are joined by a plug wrap.

In some embodiments the combined axial length of the first and second filter portions is around 12 mm and the step of combining the terminal filter element with the substrate is performed using a combining machine configured for combining terminal filter elements having an axial length of 12 mm. In this respect, the two filter portions may be processed using standard equipment.

In a third aspect of the eighth mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the eighth mode and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a fourth aspect of the eighth mode, there is provided a method of using a smoking substitute system according to the second aspect of the eighth mode, the method comprising inserting the article/consumable into the device, and heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

Ninth Mode of the Disclosure

At its most general, the ninth mode of the present disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable an aerosol-forming substrate at least partly formed of an extruded plant material.

According to a first aspect of the ninth mode, the present disclosure provides an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate at least partly comprising a rod of extruded plant material wherein the article further comprises a terminal filter element at the downstream axial end and an upstream filter element upstream and axially spaced from the terminal filter element.

Extruded plant material is typically more compacted/more dense than other types of plant material typically used in smoking substitute articles. By providing an aerosol-forming substrate formed of or comprising a rod of extruded plant material, the user of a smoking substitute system having an external heater is provided with an aerosol having an increased concentration of volatile compounds and thus an enhanced medicinal/recreational effect. The filter elements act to remove particular matter from the vapour/aerosol generated by heating the extruded plant material with the axial spacing therebetween allowing a greater axial length of article which allows an increased volume for cooling/mixing of the vapour/aerosol.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol i.e., with the downstream end of the consumable being the mouth end or outlet where the aerosol exits the consumable for inhalation by the user. The upstream end of the consumable is the opposing end to the downstream end.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate at least partly comprises extruded plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

Extruded tobacco can produced by forming a liquid mixture of powered tobacco and a binding agent such as a gum (e.g., xanthan, guar, arabic and/or locust bean gum). The liquid mixture is heated and then extruded through a die to form the tube-shaped extrudate.

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators—the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g., wood fibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt % e.g., between 6-9 wt % such as between 7-9 wt %.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry, etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed/dosed throughout the aerosol-forming substrate, e.g., it may be added to the liquid mixture of plant material prior to extrusion.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm.

It may have an axial length of between 10 and 15 mm.

The extruded rod of plant material may form the entire aerosol-forming substrate in which case it may have an axial length of between 10 and 15 mm. The axial bore through the extruded rod of plant material may extend through the entire axial length of the extrudate e.g., it may have an axial length of between 10 and 15 mm. The axial upstream end of the axial bore is at the axial upstream end of the article/consumable.

The aerosol-forming substrate may be circumscribed by a wrapping layer, e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The rod of extruded plant material may have an axial bore adapted to receive an external heating element.

The axial bore in the extruded rod of plant material may have a diameter of between 1 and 3 mm, e.g., around 2 mm.

The article/consumable comprises a terminal filter element at the downstream/mouth end of the article/consumable. There is also an upstream filter element which is axially spaced from the terminal filter element. The upstream filter element may be axially adjacent the substrate.

The or at least one of the filter element(s) (e.g., the terminal filter element and/or upstream filter element) may be comprised of cellulose acetate or polypropylene tow. The or at least one of the filter element(s) (e.g., the terminal filter element and/or upstream filter element) may be comprised of activated charcoal. The or at least one of the filter element(s) (e.g., the terminal filter element and/or upstream filter element) may be comprised of paper. The or at least one of the filter element(s) (e.g., the terminal filter element and/or upstream filter element) may be comprised of plant material, e.g., extruded plant material. The or each filter element may be at least partly (e.g., entirely) circumscribed with a plug wrap e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The or at least one of the filter element(s) may be a solid filter element. The or at least one of the filter element(s) may be a hollow bore filter element. The or each hollow bore filter may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The or at least one of the filter elements e.g., the terminal filter element may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavourant, e.g., a liquid flavourant as described above.

The capsule can be crushed by the user during smoking of the consumable to release the flavourant. The capsule may be located at the axial centre of the terminal filter element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and a/the filter element and/or between the two filter elements. The aerosol cooling element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximise heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity between the aerosol-forming substrate and the downstream end of the consumable. For example, it may be between the aerosol-forming substrate and a/the filter element and/or between the two filter elements. The spacer element may comprise a tubular element e.g., a cardboard or plastics material tube. The spacer element may be circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the ninth mode, there is provided a system comprising an article/consumable according to the first aspect of the ninth mode and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable.

The diameter of the axial bore of the extruded rod of plant material (where present) preferably matches the diameter of the elongated rod/tube heater.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the ninth mode, there is provided a method of using a system according to the second aspect of the ninth mode, the method comprising:

inserting the article/consumable into the device; and heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into the device such that the heating element is received in the axial bore of the aerosol-forming substrate (where present).

Tenth Mode of the Disclosure

At its most general, the tenth mode of the present disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable. The aerosol-forming article of the disclosure provides a means for the user to tailor their experience thereby facilitating increased enjoyment of the product.

According to a first aspect of the tenth mode, there is provided a heat not burn (HNB) consumable comprising an aerosol-forming substrate, and a terminal filter element, wherein the axial length of the terminal filter element is adjustable.

In this way, the user is able to tailor their experience of the consumable to meet their own requirements. A user may decide to retain the entire axial length of the terminal filter element thereby providing the highest level of filtration and a less harsh experience. Alternatively they may decide to adjust the axial length of the filter element to vary the intensity. For example, they may reduce the axial length of the terminal filter element to reduce the level of filtration and increase the intensity of their experience. The disclosure removes the need for complex and expensive HNB devices which provide different levels of heating to vary the intensity of the user experience. In contrast, the present disclosure provides a consumable with an integrated variability in intensity, such that the user experience can be tailored regardless of capabilities of the device which is used to heat the consumable.

The variable intensity provided by the present disclosure offers particular advantages when applied to a HNB consumable. A traditional cigarette provides a relatively constant level/intensity of smoke throughout its use, until the rod of smokable material has been entirely combusted and the intensity drops to zero. However, the intensity of the aerosol generated by a HNB consumable tends to decline more gradually through its use, as the quantity of volatile substances (e.g., nicotine, humectant and/or flavourant) within the aerosol-forming substrate decreases. The present disclosure offers a means for the user to compensate for this decline in intensity during use of the HNB consumable. For example, as the user begins to sense that the intensity of the inhaled aerosol has decreased, they may adjust the axial length of the filter element to increase the intensity again, thereby extending the operable lifetime of the HNB consumable, which in turn leads to cost savings and lower levels of waste.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the consumable.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol i.e., with the downstream end of the consumable being the mouth end or outlet where the aerosol exits the consumable for inhalation by the user. The upstream end of the consumable is the opposing end to the downstream end.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m2, e.g., greater than or equal to 110 g/m2 such as greater than or equal to 120 g/m2.

The sheet may have a grammage of less than or equal to 300 g/m2 e.g., less than or equal to 250 g/m2 or less than or equal to 200 g/m2.

The sheet may have a grammage of between 120 and 190 g/m2.

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material. The aerosol-forming substrate may comprise from 50 to 80 wt % plant material, for example from 50 to 75 wt %, from 55 to 80 wt %, from 55 to 75 wt %, from 50 to 70 wt %, from 55 to 70 wt %, from 60 to 75 wt % or from 60 to 70 wt %.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators—the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g., wood fibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt % e.g., between 6-9 wt % such as between 7-9 wt %.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be circumscribed by a wrapping layer e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The consumable comprises a terminal filter element. It may further comprise an upstream filter element, upstream from the terminal filter element. The two filter elements may be adjacent one another or may be spaced apart. The upstream filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The or at least one of the filter element(s) (e.g., the terminal filter element) may be comprised of cellulose acetate or polypropylene tow. The or at least one filter element(s) (e.g., the terminal filter element) may be comprised of activated charcoal. The or at least one of filter element(s) (e.g., the terminal element) may be comprised of paper. The or each filter element (e.g., the terminal filter element) may be comprised of extruded plant material. The or each filter element may be circumscribed with a plug wrap e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The upstream filter element may be a solid filter element. The upstream filter element may be a hollow bore filter element having a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

The axial length of the terminal filter element is adjustable. In some embodiments, the axial length of the terminal filter element is reducible. Herein, “axial length” when used to describe a dimension of a filter or filter element refers to the length in the direction of the airflow through the consumable. Thus, when the axial length of the terminal filter element is adjusted the effective filtration length (i.e., the length of filter through which the vapour/aerosol must pass before inhalation) is adjusted. For example, a reduction of the axial length of the terminal filter element will reduce the length of terminal filter element through which the aerosol passes within the consumable and reduce the extent of filtration accordingly.

In some embodiments, the axial length of the terminal filter element is adjustable by the removal of one or more terminal portions of the terminal filter element. In this way, a discrete portion or element of the terminal filter element is removed from the consumable, leaving a residual portion in place which is of reduced axial length, thereby offering a reduced level of filtration and increased intensity.

In some embodiments, the terminal filter element comprises a plurality of filter portions in axial abutment with one another wherein one or more filter portions is/are removable from the consumable to adjust the axial length of the terminal filter element. In this way, one or more filter portions may be more easily removed from the residual one or more filter portions of the terminal filter element so that the user experience is more easily tailored. In some embodiments, the terminal filter element comprises two filter portions in axial abutment with one another. In some embodiments, the terminal filter element comprises three filter portions in axial abutment with one another. In some embodiments, the terminal filter element comprises four filter portions in axial abutment with one another. Providing an increased number of discrete, separable portions within the filter element provides finer adjustability of the filtration level provided by the consumable.

The terminal filter element may comprise a circumscribing tipping layer e.g., a tipping paper layer for holding the filter portions in abutment and for joining the terminal filter element to the upstream elements forming the consumable. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

In some embodiments, the one or more filter portions of the terminal filter element are removable by breaking the tipping paper along a region of weakness. In some embodiments, the region of weakness comprises a line of weakness in the tipping paper which overlies a junction between two axially abutting filter portions. In some embodiments, the line of weakness comprises a linear array of perforations in the tipping layer of the consumable.

In some embodiments, at least one of the plurality of filter portions is adapted to provide a reduced level of filtration. For example, at least one of the filter portions may be a hollow bore filter portion having a hollow axial bore.

One or more of the filter portions may be a solid filter portion (i.e., without any axial bore).

In some embodiments, the hollow bore filter portion may be upstream from the downstream axial end of the consumable.

In some embodiments, the solid filter portion may be at the downstream axial end of the consumable.

In some embodiments, the terminal filter element comprises an upstream hollow bore filter portion and a downstream solid filter portion with the region of weakness/line of perforations in the tipping paper substantially aligned with the join between the upstream hollow bore filter portion and the downstream solid filter portion.

In this way, a more dramatic increase in intensity is attainable by the removal of a terminal filter portion of the terminal filter element, since one or more remaining filter portion is not only of shorter axial length relative to the initial terminal filter element, but is specifically adapted to provide a reduced level of filtration.

The upstream filter element or one of the solid filter portions of the terminal filter element may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavourant, e.g., any of the flavourants listed above. The capsule can be crushed by the user during smoking of the consumable to release the flavourant. The capsule may be located at the axial centre of the upstream filter element or one of the solid filter portions of the terminal filter element.

In a second aspect of the tenth mode, there is provided an aerosol-forming article (e.g., a smoking substitute article or a heat not burn (HNB) consumable) comprising an aerosol-forming substrate and a terminal filter element wherein the axial length of the terminal filter element is adjustable and wherein the terminal filter element comprises a hollow bore filter portion and a solid filter portion.

The aerosol-forming substrate in the second aspect of the tenth mode may be as described above for the first aspect of the tenth mode. There may be an upstream filter element as described for the first aspect of the tenth mode. There may be an aerosol-cooling element and/or a spacer element as described above for the first aspect of the tenth mode.

At least one of the filter portions may be comprised of cellulose acetate or polypropylene tow. At least one filter portions may be comprised of activated charcoal. At least one of filter portions may be comprised of paper. At least one of filter portions may be comprised of extruded plant material. Each filter portion may be circumscribed with a plug wrap e.g., a paper plug wrap.

The filter portions may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the terminal filter element (and the upstream filter element) may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The terminal filter element comprises a hollow bore filter portion and a solid filter portion. They may be in axial abutment or they may be spaced by one or more further filter portions. The solid bore filter portion may be the terminal filter portion i.e., at the downstream axial end of the article. In this case, the hollow bore filter element will be upstream of the solid filter portion e.g., axially adjacent and upstream of the solid filter portion.

The axial length of the terminal filter element is adjustable/reducible as described above for the first aspect of the tenth mode, i.e., by removal of the terminal portion of the terminal filter element.

The terminal filter element may comprise a circumscribing tipping layer as described for the first aspect of the tenth mode, e.g., a tipping paper layer for holding the filter portions in abutment and for joining the terminal filter element to the upstream elements forming the consumable. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element. In some embodiments, the tipping paper comprises a region of weakness/line of perforations substantially aligned with the upstream axial end of the terminal (e.g., solid) filter portion e.g., at a join between the terminal (e.g., solid) and upstream (e.g., hollow bore) filter portions.

In some embodiments of the first or second aspect of the tenth mode, the consumable/article may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and the upstream filter element/the upstream filter portion of the terminal filter element and/or between the upstream filter element and the upstream filter portion of the terminal filter element. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximise heat exchange and cooling of the aerosol.

The consumable/article may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the consumable. It may be provided between the aerosol-forming substrate and the upstream filter element/the upstream filter portion of the terminal filter element and/or between the upstream filter element and the upstream filter portion of the terminal filter element. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may be a tubular element e.g., it may comprise a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a third aspect of the tenth mode, there is provided a smoking substitute system comprising a HNB consumable according to the first aspect of the tenth mode or an article according to the second aspect of the tenth mode and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a fourth aspect of the tenth mode, there is provided a method of using a smoking substitute system according to the third aspect of the tenth mode, the method comprising:

inserting the consumable/article into the device; and

heating the consumable/article using the heating element.

In some embodiments, the method comprises inserting the consumable/article into a cavity within the main body and penetrating the consumable with the heating element upon insertion of the consumable/article. For example, the heating element may penetrate the aerosol-forming substrate in the consumable/article.

The method may further comprise reducing the axial length of the terminal filter element.

Eleventh Mode of the Disclosure

At its most general, the eleventh mode of the present disclosure relates to an aerosol-forming article e.g., a smoking substitute article such as an HNB consumable having filter elements of different axial lengths.

According to a first aspect of the eleventh mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and a plurality of filter elements having different axial lengths.

By providing a plurality of filter elements having different axial lengths, the vapour filtering and mixing performance can be tailored during manufacture to enhance the user's experience and to reduce the inhalation of undesirable components of the vapour.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m2, e.g., greater than or equal to 110 g/m2 such as greater than or equal to 120 g/m2.

The sheet may have a grammage of less than or equal to 300 g/m2 e.g., less than or equal to 250 g/m2 or less than or equal to 200 g/m2.

The sheet may have a grammage of between 120 and 190 g/m2.

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators—the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g., wood fibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt % e.g., between 6-9 wt % such as between 7-9 wt %.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be at least partly circumscribed by a wrapping layer e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The article/consumable comprises at least two filter elements having a different axial length. There may be a terminal filter element at the downstream/mouth end of the article/consumable. There may be an upstream filter element upstream of the terminal filter element but downstream of the aerosol-forming substrate.

The terminal filter element and upstream filter element may be axially adjacent one another or may be spaced apart. The upstream filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

At least one of the filter elements (e.g., the terminal filter element and/or upstream filter element) may be comprised of cellulose acetate or polypropylene tow. At least one of the filter elements (e.g., the terminal filter element and/or upstream filter element) may be comprised of activated charcoal. At least one of the filter elements (e.g., the terminal element and/or upstream filter element) may be comprised of paper. At least one of the filter elements (e.g., the terminal element and/or upstream filter element) may be comprised of extruded plant material. The or each filter element may be circumscribed with a plug wrap e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer).

In some embodiments, the axial length of the terminal filter element is greater than the axial length of the upstream filter element. For example, the axial length of the terminal filter element may be 1 mm or more greater than the axial length of the upstream filter element. The axial length of the terminal filter element may be 2 mm or 3 mm or 4 mm or 5 mm or more greater than the axial length of the upstream filter element.

The axial length of the terminal filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm such as around 12 mm.

In some embodiments, the upstream filter element may have an axial length of 10 mm or less and the terminal filter element has an axial length greater than 10 mm, e.g., around 12 mm.

The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be a solid filter element. The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be a hollow bore filter element.

It is preferred that the terminal filter element is a hollow bore filter element with a greater axial length than the upstream filter element. The upstream filter element may be a hollow bore filter element.

Providing a shorter upstream filter element results in a greater concentration of the volatile compound (e.g., nicotine) at the terminal filter element because there is less condensation of the volatile compound on the upstream filter element. This effect is further increased in embodiments where the upstream filter element is a hollow bore filter element as there is an unimpeded path through the upstream filter element. The increased length of the terminal hollow bore filter in preferred embodiments provides for good mixing (within the bore) of the vapour components (including the increased volatile compound component).

The or each hollow bore filter element may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm. Where both the upstream filter element and terminal filter element are hollow bore filter elements, the upstream filter element preferably has a larger bore diameter than the terminal filter element.

The terminal hollow bore filter element may have an increased density or increased hardness than the upstream filter element i.e., the upstream filter element may have an increased porosity than the terminal filter element. This is to increase the flow and mixing of the vapour/aerosol within the hollow bore of the terminal filter element.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and the upstream filter element and/or between the two filter elements. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximise heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable. For example, it may be provided between the aerosol-forming substrate and the upstream filter element and/or between the two filter elements. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may be a tubular spacer element e.g., it may comprise a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length greater than the axial length of the terminal filter element. It may have any axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the eleventh mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the eleventh mode and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the eleventh mode, there is provided a method of using a smoking substitute system according to the second aspect of the eleventh mode, the method comprising:

inserting the article/consumable into the device; and

heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

Twelfth Mode of the Disclosure

At its most general, the twelfth mode of the present disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable having hollow bore filter elements of different bore diameters.

According to a first aspect of the twelfth mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and a plurality of hollow bore filter elements having different internal bore diameters.

By providing a plurality of hollow bore filter elements having different internal bore diameters, the vapour filtering and mixing performance can be tailored during manufacture to enhance the user's experience.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m2, e.g., greater than or equal to 110 g/m2 such as greater than or equal to 120 g/m2.

The sheet may have a grammage of less than or equal to 300 g/m2 e.g., less than or equal to 250 g/m2 or less than or equal to 200 g/m2.

The sheet may have a grammage of between 120 and 190 g/m2.

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators—the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g., wood fibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt % e.g., between 6-9 wt % such as between 7-9 wt %.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be at least partly circumscribed by a wrapping layer e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The article/consumable comprises at least two hollow bore filter elements having a different internal axial bore diameters. There may be a terminal hollow bore filter element at the downstream/mouth end of the article/consumable. There may be an upstream hollow bore filter element upstream of the terminal filter element but downstream of the aerosol-forming substrate.

The terminal filter element and upstream filter element may be axially adjacent one another or may be spaced apart. The upstream filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

At least one of the filter elements (e.g., the terminal filter element and/or upstream filter element) may be comprised of cellulose acetate or polypropylene tow. At least one of the filter elements (e.g., the terminal filter element and/or upstream filter element) may be comprised of activated charcoal. At least one of the filter elements (e.g., the terminal filter element and/or upstream filter element) may be comprised of paper. At least one of the filter elements (e.g., the terminal filter element and/or upstream filter element) may be comprised of extruded plant material. The or each filter element may be circumscribed with a plug wrap e.g., a paper plug wrap.

Each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer).

In some embodiments, the axial length of the terminal filter element is greater than the axial length of the upstream filter element. For example, the axial length of the terminal filter element may be 1 mm or more greater than the axial length of the upstream filter element. The axial length of the terminal filter element may be 2 mm or 3 mm or 4 mm or 5 mm or more greater than the axial length of the upstream filter element.

The axial length of the terminal filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm such as around 12 mm.

In some embodiments, the upstream filter element may have an axial length of 10 mm or less and the terminal filter element has an axial length greater than 10 mm, e.g., around 12 mm.

Each hollow bore filter element may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm. The upstream hollow bore filter element preferably has a larger bore diameter than the terminal hollow bore filter element. For example, the upstream hollow bore filter element may have a bore diameter that is 1 mm or more greater than the bore diameter of the terminal filter element. For example, the upstream hollow bore filter element may have a bore diameter of 3 or 3.5 mm whilst the terminal filter element may have a bore diameter of around 2 mm.

By providing a terminal filter element with a reduced bore diameter (compared to the upstream hollow bore filter element), a greater mixing effect is achieved within the terminal hollow bore filter element as all of the components of the vapour/aerosol are forced to co-locate within the more restricted hollow bore. The increased length of the terminal hollow bore filter in preferred embodiments also provides for good mixing (within the bore) of the vapour components.

The terminal hollow bore filter element may have an increased density or increased hardness than the upstream filter element i.e., the upstream filter element may have an increased porosity than the terminal filter element. This is to increase the flow and mixing of the vapour/aerosol within the hollow bore of the terminal filter element.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and the upstream filter element and/or between the two filter elements. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximise heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable. For example, it may be provided between the aerosol-forming substrate and the upstream filter element and/or between the two filter elements. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may be a tubular spacer element e.g., it may comprise a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length greater than the axial length of the terminal filter element. It may have any axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the twelfth mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the twelfth mode and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

In some embodiments, the heating element is a rod-shaped heater having a diameter of around 2 mm (e.g., 2.1 mm). The provision of a bore diameter of around 3 mm or 3.5 mm in the upstream hollow bore filter element in the article may be particularly suited to use with a device having such a rod heater as the plant material, e.g., tobacco closest to the rod heater (which will be subjected to the highest temperatures) will be axially aligned with the upstream axial end of the bore in the upstream hollow bore filter element so that the vapour released from this axially aligned portion of plant material can flow directly into the bore of the upstream hollow bore filter element. Accordingly, in preferred embodiment of the system, the internal diameter of the bore of the upstream hollow bore filter element is greater than the external diameter of the rod heater.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the twelfth mode, there is provided a method of using a smoking substitute system according to the second aspect of the twelfth mode, the method comprising:

inserting the article/consumable into the device; and

heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

Thirteenth Mode of the Disclosure

At its most general, the thirteenth mode of the present disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable having filter elements of different hardness.

According to a first aspect of the thirteenth mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and a plurality of filter elements wherein at least two filter elements have a different hardness from one another.

By providing a plurality of filter elements of different hardness, the vapour filtering performance can be tailored during manufacture to enhance the user's experience and to reduce the inhalation of undesirable components of the vapour. The respective hardness of the filter elements can also be used to tailor the resistance to draw (RTD) of the article with a harder filter element increasing the RTD more than a less hard filter element.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m2, e.g., greater than or equal to 110 g/m2 such as greater than or equal to 120 g/m2.

The sheet may have a grammage of less than or equal to 300 g/m2 e.g., less than or equal to 250 g/m2 or less than or equal to 200 g/m2.

The sheet may have a grammage of between 120 and 190 g/m2.

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators—the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g., wood fibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt % e.g., between 6-9 wt % such as between 7-9 wt %.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be at least partly circumscribed by a wrapping layer e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The article/consumable comprises at least two filter elements. There may be a terminal filter element at the downstream/mouth end of the article/consumable. There may be an upstream filter element upstream of the downstream axial end but downstream of the aerosol-forming substrate.

The terminal filter element and upstream filter element may be axially adjacent one another or may be spaced apart. The upstream filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

At least one of the filter elements (e.g., the terminal filter element and/or upstream filter element) may be comprised of cellulose acetate or polypropylene tow. At least one of the filter elements (e.g., the terminal filter element and/or upstream filter element) may be comprised of activated charcoal. At least one of the filter elements (e.g., the terminal element and/or upstream filter element) may be comprised of paper. At least one of the filter elements (e.g., the terminal element and/or upstream filter element) may be comprised of plant material, e.g., extruded plant material. The or each filter element may be circumscribed with a plug wrap e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer).

In some embodiments, the upstream and terminal filter elements have different axial lengths. For example, the axial length of the terminal filter element may be greater than the axial length of the upstream filter element. For example, the axial length of the terminal filter element may be 1 mm or more greater than the axial length of the upstream filter element. The axial length of the terminal filter element may be 2 mm or 3 mm or 4 mm or 5 mm or more greater than the axial length of the upstream filter element.

The axial length of the terminal filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm such as around 12 mm.

In some embodiments, the upstream filter element may have an axial length of 10 mm or less and the terminal filter element has an axial length greater than 10 mm, e.g., around 12 mm.

The or at least one of the filter element(s) (e.g., the terminal filter element and/or upstream filter element) may be a solid filter element. The or at least one of the filter element(s) (e.g., the terminal filter element and/or upstream filter element) may be a hollow bore filter element.

It is preferred that the terminal filter element is a hollow bore filter element with a greater axial length than the upstream filter element. The upstream filter element may be a hollow bore filter element.

Providing a shorter upstream filter element results in a greater concentration of the volatile compound (e.g., nicotine) at the terminal filter element because there is less condensation of the volatile compound on the upstream filter element. This effect is further increased in embodiments where the upstream filter element is a hollow bore filter element as there is an unimpeded path through the upstream filter element. The increased length of the terminal hollow bore filter in preferred embodiments provides for good mixing (within the bore) of the vapour components (including the increased volatile compound component).

The or each hollow bore filter element may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm. Where both the upstream filter element and terminal filter element are hollow bore filter elements, the upstream filter element preferably has a larger bore diameter than the terminal filter element.

The terminal hollow bore filter element may have an increased density or increased hardness than the upstream filter element i.e., the upstream filter element may have an increased porosity than the terminal filter element. This is to increase the flow and mixing of the vapour/aerosol within the hollow bore of the terminal filter element. The increased hardness/reduced porosity of the terminal filter element forces the aerosol/vapour to enter the axial bore through the terminal filter element (since the passage through the body of the terminal filter element is impeded) and this forces the components within the vapour/aerosol to co-locate within the bore thus increasing mixing. Furthermore, the increased hardness of the terminal filter element may reduce the need for filter plasticisers at the downstream (mouth) end of the article.

Hardness of a filter element can be measured using a standard densitometer such as a Borgwaldt densitometer DD60A. During such measurement, the diameter of the filter element is measured and then a crushing load (e.g., 3 kg) is applied and the remaining diameter (parallel to the applied force) measured after a given time. A percentage hardness is calculated as the remaining diameter divided by the initial diameter×100.

In some embodiments, the percentage hardness of the terminal filter element is 3% or more, 4% or more or 5% or more greater than the hardness of the upstream filter element.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and the upstream filter element and/or between the two filter elements. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximise heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable. For example, it may be provided between the aerosol-forming substrate and the upstream filter element and/or between the two filter elements. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may be a tubular spacer element e.g., it may comprise a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length greater than the axial length of the terminal filter element. It may have any axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the thirteenth mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the thirteenth mode and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the thirteenth mode, there is provided a method of using a smoking substitute system according to the second aspect of the thirteenth mode, the method comprising:

inserting the article/consumable into the device; and

heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

Fourteenth Mode of the Disclosure

At its most general, the fourteenth mode of the present disclosure relates to an aerosol-forming article e.g., a smoking substitute article such as an HNB consumable having an air flow path into the consumable upstream of a terminal filter element.

According to a first aspect of the fourteenth mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and a hollow bore terminal filter element at a downstream axial end of the article/consumable wherein the article comprises at least one radial air flow path into the aerosol-forming substrate.

By providing at least one radial air flow path into the aerosol-forming substrate, air can be drawn into the aerosol-forming substrate as the user inhales and this air can help to vaporise volatile components (e.g., physiologically active volatile compounds and/or humectants) within the aerosol-forming substrate. In turn, this can increase or maximise the vapour e.g., the visible vapour (or Total Particulate Matter (TPM)) which users often find desirable to mimic the effect of traditional smoking. The cross-sectional area of the at least one air flow path and/or the number of radial air flow paths can be tailored to tailor the resistance to draw (RTD) of the article/consumable.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

In some embodiments, there is a plurality of radial air flow paths which may be circumferentially-arranged around the aerosol-forming article. There may be a plurality of axially spaced, circumferentially arranged rows of radial flow paths.

The aerosol-forming substrate may be circumscribed by a wrapping layer e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The radial air flow path(s) may be provided by one or more ventilation holes provided in the wrapping layer. There may be a plurality of ventilation holes circumferentially arranged around the aerosol-forming substrate, e.g., a plurality of axially spaced, circumferentially arranged rows of ventilation holes.

In some embodiments, the article/consumable may further comprise a spacer element or an aerosol-cooling element upstream and axially adjacent the terminal filter element.

There may also be an upstream filter element provided upstream of the terminal filter element and downstream of the aerosol-forming substrate. The upstream filter element may be adjacent the downstream end of the aerosol-forming substrate, e.g., between the aerosol-forming substrate and the spacer/aerosol-cooling element.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end. The axial direction of the article/consumable is aligned with the flow direction of the vapour/aerosol i.e., extends between the upstream and downstream ends of the article/consumable. The radial air flow path extends substantially perpendicularly to the axial direction/flow direction of the vapour/aerosol.

The spacer/aerosol-cooling element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer. The upstream filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The or each filter element is formed of a smoke-permeable material. The terminal and/or upstream filter element(s) may be comprised of cellulose acetate or polypropylene tow. The terminal and/or upstream filter element(s) may be comprised of activated charcoal. The terminal and/or upstream filter element(s) may be comprised of paper. The terminal and/or upstream filter element(s) may each be circumscribed with a respective plug wrap e.g., a paper plug wrap.

The porosity of the upstream filter element may be greater than the porosity of the terminal filter element.

The terminal and/or upstream filter element(s) may each have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The upstream filter element may be a solid filter element or may be a hollow bore filter element comprising an axial bore.

The terminal filter element and optionally the upstream filter element may each have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm. The diameter of the axial bore in the (hollow bore) upstream filter element may be greater than the diameter of the bore in the terminal filter element.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element (e.g., the adjacent spacer element or aerosol-cooling element).

The aerosol-cooling element is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximise heat exchange and cooling of the aerosol.

The spacer element defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable e.g., between the upstream and terminal filter elements. The spacer element acts to allow both cooling and mixing of the aerosol. The spacer element may have a tubular wall e.g., formed of cardboard.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m2, e.g., greater than or equal to 110 g/m2 such as greater than or equal to 120 g/m2.

The sheet may have a grammage of less than or equal to 300 g/m2 e.g., less than or equal to 250 g/m2 or less than or equal to 200 g/m2.

The sheet may have a grammage of between 120 and 190 g/m2.

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators—the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g., wood fibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt % e.g., between 6-9 wt % such as between 7-9 wt %.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

In a second aspect of the fourteenth mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the fourteenth mode and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the fourteenth mode, there is provided a method of using a smoking substitute system according to the second aspect of the fourteenth mode, the method comprising:

inserting the article/consumable into the device; and

heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

Fifteenth Mode of the Disclosure

At its most general, in the fifteenth mode of the disclosure, a first aspect of the present disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable with a filter having an adsorbent additive.

According to the first aspect of the fifteenth mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and a terminal filter element at the downstream axial end of the article wherein the terminal filter element comprises an adsorbent additive.

By providing a terminal filter element with an adsorbent, the terminal filter element can remove unwanted/harmful substances of the aerosol drawn through the terminal filter element by the user prior to inhalation. In particular, the adsorbent additive is able to remove unwanted/harmful substances that are not removed by the filter alone.

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

Optionally, the adsorbent additive is selected from one or more of a zeolite, an activated carbon, a silica gel, a clay, a porous polymer and activated alumina. Preferably, the adsorbent additive is activated carbon.

In some embodiments, at least a portion of the adsorbent additive is in the form of a free-flowing powder/granular/fine particle adsorbent. By having the adsorbent additive in the form of smaller flowing particles, a larger surface area and packing density can be achieved.

In some embodiments, at least a portion of the adsorbent additive is in the form of pellets/tablets/pills/beads/fibres. By having the adsorbent additive in the form of larger solid particles, such as pellets, the adsorbent additive can contribute to the structural integrity of the filter and the article.

In some embodiments, the adsorbent additive is provided predominantly within a discrete location within the terminal filter element. For example, at least a portion, or preferably all, of the adsorbent additive is sandwiched between an upstream terminal filter portion and a downstream terminal filter portion. By packing the adsorbent additive between two filter portions at the terminal end of the article, the adsorbent additive is held in place and the amount of adsorbent additive may be varied easily between articles during manufacture without changing the nature of the two filter portions.

The terminal filter element may comprise one or more cavities/holes/voids in which at least a portion, or preferably all, of the adsorbent additive is held. By having one or more cavities/holes/voids in the filter the adsorbent additive can be located in specified pockets and configurations throughout the filter.

In some embodiments, at least a portion, or preferably all, of the adsorbent additive is impregnated in the terminal filter element. By impregnating the terminal filter element with adsorbent additive, the filter element can be prepared beforehand as a standalone portion. Furthermore, there is a decreased chance of adsorbent additive spillage if the structural integrity of the article is compromised.

Optionally, the adsorbent additive is evenly distributed throughout the entire terminal filter element. By distributing the terminal filter element with adsorbent additive throughout, a maximum filtering and adsorbing effect may be achieved.

The adsorbent additive may account for up to 50%, 40%, 30%, 20%, 10%, 5%, 2% or 1% by mass of the terminal filter element.

The adsorbent additive removes hazardous substances from the aerosol as it passes through the filter element. In particular, the adsorbent additive removes tobacco-specific nitrosamines (TSNAs) from the aerosol. TSNAs include nicotine-derived nitrosamine ketone (NNK), N-nitrosonornicotine (NNN), N′-nitrosoanatabine (NAT) and N-nitrosoanabasine (NAB).

At its most general, a second aspect of the fifteenth mode of the present disclosure relates to an aerosol-forming article e.g., a smoking substitute article such as an HNB consumable with a filter comprising a polar solvent.

According to the second aspect of the fifteenth mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and at least one filter element wherein the at least one filter element comprises a polar solvent.

By providing a filter element comprising a polar solvent, the filter element can remove unwanted/harmful particulate matter in the vapour at the same time as the polar solvent dissolves and removes tobacco-specific nitrosamines (TSNAs) from the vapour. TSNAs include nicotine-derived nitrosamine ketone (NNK), N-nitrosonornicotine (NNN), N′-nitrosoanatabine (NAT) and N-nitrosoanabasine (NAB).

Optional features will now be set out. These are applicable singly or in any combination with any aspect.

In some embodiments, the polar solvent is one or more polar solvent(s) selected from water and polar organic solvents. In some embodiments, the one or more polar organic solvent(s) is/are selected from ethanol, isopropyl alcohol and dimethylsulfoxide.

The polar solvent may be equally dispersed throughout the filter element. Alternatively it may be provided in discrete locations or may be concentrated in discrete locations (e.g., it may be provided in a axially central portion).

In some embodiments, at least some of the polar solvent may be contained in one or more frangible capsules that are configured to release the polar solvent upon rupture so that polar solvent does not dissipate or evaporate before use.

In some embodiments, the or each frangible capsule is a crushable capsule/crush-ball configured to break and release the polar solvent when crushed/broken.

In some embodiments, the or each capsule is a thermally labile capsule configured to melt/deform/rupture and release the polar solvent when heated, such as when a heated aerosol is drawn through the filter element by the user.

In some embodiments, the polar solvent may account for up to 50%, up to 40%, up to 30%, up to 20%, up to 10%, up to 5%, up to 2% or up to 1% by mass of the filter element. The aerosol-forming article of the first or second aspect of the fifteenth mode is preferably a heat-not-burn (HNB) consumable.

The article/consumable comprises an aerosol-forming substrate which is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m2 such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m² e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m2.

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators—the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g., wood fibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt % e.g., between 6-9 wt % such as between 7-9 wt %.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be circumscribed by a wrapping layer e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

In addition to the terminal filter element, the article/consumable of the first aspect of the fifteenth mode may further comprise an upstream filter element.

The filter element comprising the polar solvent of the second aspect of the fifteenth mode may be a terminal filter element provided at the downstream axial end of the article. In this case, there may be an additional, upstream filter element which may, for example, be axially adjacent the aerosol-forming substrate. The upstream filter element may or may not comprise a polar solvent.

The filter element comprising the polar solvent may be an upstream filer element i.e., upstream of the downstream axial end of the article. In this case, there may be an additional, terminal filter element at the downstream axial end of the article. The terminal filter element may or may not comprise a polar solvent.

The or at least one of the filter element(s) or filter portions (e.g., the terminal filter element (portions)/upstream filter element) may be comprised of cellulose acetate or polypropylene tow. The or at least one of the filter element(s) or filter portions (e.g., the terminal filter element (portions)/upstream filter element) may be comprised of activated charcoal. The or at least one of the filter element(s) or filter portions (e.g., the terminal filter element (portions)/upstream filter element) may be comprised of paper. The or at least one of the filter element(s) or filter portions (e.g., the terminal filter element (portions)/upstream filter element) may be comprised of extruded plant material. The or each filter element may be circumscribed with a plug wrap e.g., a paper plug wrap.

The or each filter element/portion may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The or at least one of the filter element(s) or filter portions may be a solid filter element. The or at least one of the filter element(s) may be a hollow bore filter element. The or each hollow bore filter may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

Where there are two filter elements (i.e., an upstream filter element and terminal filter element) they may be adjacent one another or which may be spaced apart. Any filter element(s) upstream of the terminal filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The or at least one of the filter elements e.g., the terminal filter element may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavourant, e.g., any of the flavourants listed above. The capsule can be crushed by the user during smoking of the article/consumable to release the flavourant. The capsule may be located at the axial centre of the terminal filter element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and the upstream or terminal filter element and/or between the upstream and terminal filter elements. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximise heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable. The spacer acts to allow both cooling and mixing of the aerosol. It may be provided between the aerosol-forming substrate and the upstream or terminal filter element and/or between the upstream and terminal filter elements. The spacer element may comprise a tubular element e.g., a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a third aspect of the fifteenth mode of the disclosure, there is provided the use of a polar solvent in a filter element of an aerosol-forming article for filtering hazardous substances from an aerosol that is drawn through the filter element.

The polar solvent, filter element and the article may all be as described in the second aspect of the fifteenth mode.

In a fourth aspect of the fifteenth mode, there is provided a smoking substitute system comprising an aerosol-forming article according to either the first aspect or the second aspect of the fifteenth mode, and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a fifth aspect of the fifteenth mode of the disclosure there is provided a use of an additive adsorbent in the terminal downstream end filter of an aerosol forming article.

Optionally, the aerosol forming article has one or more of the optional features described in the first aspect of the fifteenth mode of the disclosure.

In a sixth aspect of the fifteenth mode, there is provided a method of using a smoking substitute system according to the fourth aspect of the fifteenth mode, the method comprising:

inserting the article/consumable into the device; and

heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

Sixteenth Mode of the Disclosure

At its most general, the sixteenth mode of the present disclosure relates to an aerosol-forming article e.g., a smoking substitute article such as an HNB consumable that provides an unimpeded flow passage around a filter element.

According to a first aspect of the sixteenth mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and at least one filter element downstream of the substrate wherein the at least one filter element is a hollow bore filter element and wherein the article has at least one unimpeded flow path along the outer surface of the filter element.

The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

According to a second aspect of the sixteenth mode, there is provided a heat-not-burn (HNB) consumable comprising an aerosol-forming substrate and at least one filter element downstream of the substrate wherein the consumable has at least one unimpeded flow path along the outer surface of the filter element.

The filter element may be a solid filter element or a hollow bore filter element.

By providing a filter element downstream of the aerosol-forming substrate, the filter element having at least one unimpeded flow path along its outer surface, it is possible to provide a flow path from the aerosol-forming substrate to the downstream axial end (mouth-end) of the consumable such that the volume of visible vapour (total particulate matter TPM) is maintained at a level desirable to the user.

Optional features will now be set out. These are applicable singly or in any combination with any aspect. The filter element may have an outer surface comprising at least one longitudinally-extending channel.

The filter element may have an outer surface comprising a plurality of flow paths along the outer surface of the filter element e.g., provided by a plurality of longitudinally-extending channels. For example, the entire of the outer surface may be convoluted/corrugated with a series of longitudinally-extending parallel channels and ridges.

The filter element may be a terminal filter element provided at the downstream axial end of the article/consumable.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapour/aerosol i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

The article/consumable may further comprise an upstream filter element upstream from the terminal filter element. The upstream filer element may be a solid or hollow bore filter element.

The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be comprised of cellulose acetate or polypropylene tow. The at least one filter element (e.g., the terminal filter element/upstream filter element) may be comprised of activated charcoal. The at least one filter element (e.g., the terminal element/upstream filter element) may be comprised of paper. The at least one filter element (e.g., the terminal element/upstream filter element) may be comprised of extruded plant material. The or each filter element may be circumscribed at its outer surface with a plug wrap e.g., a paper plug wrap. The plug wrap will conform to the longitudinally-extending channels on the outer surface of the filter element where provided. This the plug warp may be corrugated.

The article/consumable may further comprise a sleeve (e.g., a paper or cardboard sleeve) at least partially (e.g., fully) circumscribing the filter element having at least one (e.g., a plurality of) longitudinally-extending channel(s). The sleeve overlays the peaks in the corrugated outer surface of the filter element and leaves the longitudinally-extending channels unimpeded.

In some embodiments, the filter element having at least one (e.g., a plurality of) longitudinally-extending channel(s) may further comprise a flavourant. The flavourant may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate. The flavourant may be provided as a flavour thread i.e., the filter element may comprise a thread (e.g., a cotton thread) soaked in flavourant. The flavour thread may be longitudinally-extending e.g., it may extend the length of the filter element e.g., along the central axis of the filter element.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporised/aerosolised and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m² e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapour generators—the resulting vapour helps carry the volatile active compounds and increases visible vapour. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %.

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g., wood fibres), jute fibres and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt % e.g., between 6-9 wt % such as between 7-9 wt %.

The flavourant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavour (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavour. The flavourant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be circumscribed by a wrapping layer e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

Where the filter element is a hollow bore filter element, the filter element may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

The terminal and upstream filter elements may be adjacent one another or may be spaced apart. The upstream filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element (and its sleeve where present) plus the wrapping layer surrounding any adjacent upstream element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and the upstream filter element and/or between the upstream and terminal filter elements. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximise heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable. For example, it may be between the aerosol-forming substrate and the upstream filter element and/or between the upstream and terminal filter elements. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may comprise a tubular element e.g., a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the sixteenth mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the sixteenth mode and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the sixteenth mode, there is provided a method of using a smoking substitute system according to the second aspect of the sixteenth mode, the method comprising: inserting the article/consumable into the device; and heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

Regarding all of the modes, the skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects may be applied to any other aspect. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect and/or combined with any other feature or parameter described herein.

SUMMARY OF THE FIGURES

So that the invention may be understood, and so that further aspects and features thereof may be appreciated, embodiments illustrating the principles of the invention will now be discussed in further detail with reference to the accompanying figures, in which:

FIG. 1 shows a first embodiment of a first mode of an HNB consumable.

FIG. 2 shows a second embodiment of the first mode of an HNB consumable.

FIG. 3 shows the first embodiment of FIG. 1 within a device forming an HNB system.

FIG. 4 shows a first embodiment of a second mode of an HNB consumable.

FIG. 5 shows a second embodiment of the second mode of an HNB consumable.

FIG. 6 shows a third embodiment of the second mode of an HNB consumable.

FIG. 7 shows the first embodiment of FIG. 4 within a device forming an HNB system.

FIG. 8 shows a first embodiment of a third mode of an HNB consumable.

FIG. 9 shows a second embodiment of the third mode of an HNB consumable.

FIG. 10 shows a third embodiment of the third mode of an HNB consumable.

FIG. 11 shows the first embodiment of FIG. 8 within a device forming an HNB system.

FIG. 12 shows a first embodiment of a fourth mode of an HNB consumable.

FIG. 13 shows a second embodiment of the fourth mode of an HNB consumable.

FIG. 14 shows the first embodiment of FIG. 12 within a device forming an HNB system.

FIG. 15 shows a first embodiment of a fifth mode of an HNB consumable.

FIG. 16 shows a second embodiment of the fifth mode of an HNB consumable.

FIG. 17 shows a third embodiment of the fifth mode of an HNB consumable.

FIG. 18 shows the first embodiment of FIG. 15 within a device forming an HNB system.

FIG. 19 shows a first embodiment of a sixth mode of an HNB consumable.

FIG. 20 shows a second embodiment of the sixth mode of an HNB consumable.

FIG. 21 shows a third embodiment of the sixth mode of an HNB consumable.

FIG. 22 shows the first embodiment of FIG. 19 within a device forming an HNB system.

FIGS. 23A and 23B show a perspective and end view, respectively, of the first embodiment of the consumable of FIG. 19.

FIGS. 24, 25, and 26 are end views of exemplary embodiments of a filter element for the sixth mode of a HNB consumable.

FIG. 27 shows a first embodiment of a seventh mode of an HNB consumable.

FIG. 28 shows a second embodiment of the seventh mode of an HNB consumable.

FIG. 29 shows a third embodiment of the seventh mode of an HNB consumable.

FIG. 30 shows the first embodiment of the seventh mode of FIG. 27 within a device forming an HNB system.

FIG. 31 shows the first embodiment of FIG. 27 within a second device forming a second HNB system.

FIG. 32 shows a first embodiment of an eighth mode of an HNB consumable.

FIG. 33 shows a second embodiment of the eighth mode of an HNB consumable.

FIG. 34 shows a third embodiment of the eighth mode of an HNB consumable.

FIG. 35 shows the first embodiment of FIG. 32 within a device forming an HNB system.

FIG. 36 shows a first embodiment of a ninth mode of an HNB consumable.

FIG. 37 shows a second embodiment of the ninth mode of an HNB consumable.

FIG. 38 shows a third embodiment of the ninth mode of an HNB consumable.

FIG. 39 shows the first embodiment of FIG. 36 within a device forming an HNB system.

FIG. 40 shows a first embodiment of a tenth mode of an HNB consumable.

FIG. 41 shows the first embodiment of the tenth mode of the HNB consumable in a second condition.

FIG. 42 shows a second embodiment of the tenth mode of an HNB consumable.

FIG. 43 shows a third embodiment of the tenth mode of an HNB consumable.

FIG. 44 shows the first embodiment of FIG. 40 within a device forming an HNB system.

FIG. 45 shows a first embodiment of an eleventh mode of an HNB consumable.

FIG. 46 shows a second embodiment of the eleventh mode of an HNB consumable.

FIG. 47 shows the first embodiment of FIG. 45 within a device forming an HNB system.

FIG. 48 shows a first embodiment of a twelfth mode of an HNB consumable;

FIG. 49 shows a second embodiment of the twelfth mode of an HNB consumable;

FIG. 50 shows the first embodiment of FIG. 48 within a device forming an HNB system.

FIG. 51 shows a first embodiment of a thirteenth mode of an HNB consumable.

FIG. 52 shows a second embodiment of the thirteenth mode of an HNB consumable.

FIG. 53 shows the first embodiment of FIG. 51 within a device forming an HNB system.

FIG. 54 shows a first embodiment of a fourteenth mode of an HNB consumable;

FIG. 55 shows a second embodiment of the fourteenth mode of an HNB consumable;

FIG. 56 shows a third embodiment of the fourteenth mode of an HNB consumable;

FIG. 57 shows the first embodiment of FIG. 54 within a device forming an HNB system.

FIG. 58 shows a first embodiment of a fifteenth mode of an HNB consumable.

FIG. 59 shows a second embodiment of the fifteenth mode of an HNB consumable.

FIG. 60 shows a third embodiment of the fifteenth mode of an HNB consumable.

FIG. 61 shows a fourth embodiment of the fifteenth mode of an HNB consumable within a device forming an HNB system.

FIG. 62 shows a fifth embodiment of the fifteenth mode of an HNB consumable.

FIG. 63 shows a sixth embodiment of the fifteenth mode of an HNB consumable.

FIG. 64 shows a seventh embodiment of the fifteenth mode of an HNB consumable.

FIG. 65 shows the fifth embodiment of the fifteenth mode within a device forming an HNB system.

FIG. 66 shows a first embodiment of a sixteenth mode of an HNB consumable.

FIG. 67 shows a second embodiment of the sixteenth mode of an HNB consumable.

FIG. 68 shows the terminal filter element of the second embodiment of the sixteenth mode.

FIG. 69 shows the second embodiment of the sixteenth mode within a device forming an HNB system.

DETAILED DESCRIPTION OF THE FIGURES First Mode of the Disclosure

As shown in FIG. 1, the HNB consumable 1 comprises an aerosol-forming substrate 2 at the upstream end of the consumable 1.

The aerosol-forming substrate comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2 comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2 is circumscribed by a paper wrapping layer 3.

The consumable 1 comprises an upstream filter element 4 and a downstream (terminal) filter element 5. The two filter elements 4, 5 and spaced by a cardboard tube spacer 6. Both filter elements 4, 5 are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements have a substantially cylindrical shape. The diameter of the upstream filter 4 matches the diameter of the aerosol-forming substrate 2. The diameter of the terminal filter element 5 is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 and the wrapping layer 3. The upstream filter element is slightly shorter in axial length than the terminal filter element at an axial length of 10 mm compared to 12 mm for the terminal filter element.

The cardboard tube spacer is longer than each of the two filter elements having an axial length of around 14 mm.

Upstream filter element 4 is a hollow bore filter element with a hollow, longitudinally-extending axial bore 14.

The terminal filter element 5 has a hollow, longitudinally-extending bore 15 that is axially offset.

The diameter of the axial bore 14 in the upstream filter 4 is slightly larger than the diameter of the off-set bore in the terminal filter element 5 having a diameter of 3 mm compared to 2 mm for the terminal filter element.

The cardboard tube spacer 6 and the upstream filter element 4 are circumscribed by the wrapping layer 3.

The terminal filter element 5 is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7. The tipping layer 7 encircles the terminal filter element 5 and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6.

FIG. 2 shows a second embodiment of a consumable 1′ which is the same as the first embodiment except that the wrapping layer 3 does not completely circumscribe the cardboard tube spacer 6 such that there is an annular gap 9 between the tipping layer 7 and the cardboard tube spacer 6 downstream of the end of the wrapping layer 3.

FIG. 3 shows the first embodiment inserted into an HNB device 10 comprising a rod-shaped heating element 20. The heating element 20 projects into a cavity 11 within the main body 12 of the device.

The consumable 1 is inserted into the cavity 11 of the main body 12 of the device 10 such that the heating rod 20 penetrates the aerosol-forming substrate 2. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5.

As the vapour cools within the upstream filter element 4 and the cardboard tube spacer 6, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Second Mode of the Disclosure

As shown in FIG. 4, an HNB consumable 1 a comprises an aerosol-forming substrate 2 a at the upstream end of the consumable 1 a.

The aerosol-forming substrate comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2 a comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 a is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2 a is circumscribed by a paper wrapping layer 3 a.

The consumable 1 a comprises an upstream filter element 4 a and a downstream (terminal) filter element 5 a. The two filter elements 4 a, 5 a and spaced by a cardboard tube spacer 6 a. Both filter elements 4 a, 5 a are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements have a substantially cylindrical shape. The diameter of the upstream filter 4 a matches the diameter of the aerosol-forming substrate 2 a. The diameter of the terminal filter element 5 a is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 a and the wrapping layer 3 a. The upstream filter element is slightly shorter in axial length than the terminal filter element at an axial length of 10 mm compared to 12 mm for the terminal filter element.

The cardboard tube spacer 6 a is longer than each of the two filter portions having an axial length of around 14 mm.

Each filter element 4 a, 5 a is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter is slightly larger than the diameter of the bore in the terminal filter having a diameter of 3 mm compared to 2 mm for the terminal filter element.

The cardboard tube spacer 6 a and the upstream filter portion 4 a are circumscribed by the wrapping layer 3 a.

The terminal filter element 5 a is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7 a. The tipping layer 7 a encircles the terminal filter portion and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6 a.

A flow restrictor element 13 a in the form of a foil disc with a single perforation 14 a having a 1 mm diameter is provided at the downstream of the of the upstream filter element 4 a, i.e., it is interposed between the upstream filter element 4 a and the cardboard tube spacer 6 a.

FIG. 5 shows a second embodiment of a consumable 1 a′ which is the same as that shown in FIG. 4 except that the terminal filter element 5 a is a solid filter element and comprises a crushable capsule 8 a (crush-ball) having a shell wall containing a liquid menthol or cherry or vanilla flavourant. The capsule 8 a is spherical and has a diameter of 3.5 mm. It is positioned within the axial centre of the terminal filter portion 5 a.

FIG. 6 shows a third embodiment of a consumable 1 a″ which is the same as the first embodiment except that the wrapping layer 3 a does not completely circumscribe the cardboard tube spacer 6 a such that there is an annular gap 9 a between the tipping layer 7 a and the cardboard tube spacer 6 a downstream of the end of the wrapping layer 3 a.

FIG. 7 shows the first embodiment inserted into an HNB device 10 a comprising a rod-shaped heating element (not shown). The heating element projects into a cavity 11 a within the main body 12 a of the device.

The consumable 1 a is inserted into the cavity 11 a of the main body 12 a of the device 10 a such that the heating rod penetrates the aerosol-forming substrate 2 a. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 a is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and nicotine from within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter portion 5 a.

After the vapour passes through the upstream filter 4 a, the nicotine, moisture and humectant are forced to co-locate as they pass through the perforation 14 a in the flow restrictor element 13 a thus effecting good mixing. The vapour flow path then increases in cross-sectional area within the cardboard tube spacer 6 a which further effects efficient mixing of the vapour components.

As the vapour cools within the cardboard tube spacer 6 a, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Third Mode of the Disclosure

As shown in FIG. 8, the HNB consumable 1 b comprises an aerosol-forming substrate 2 b at the upstream end of the consumable 1 b.

The aerosol-forming substrate comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2 b comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 b is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2 b is circumscribed by a paper wrapping layer 3 b.

The consumable 1 b comprises an upstream filter element 4 b and a downstream (terminal) filter element 5 b. The two filter elements 4 b, 5 and spaced by a cooling element 6 b. Both filter elements 4 b, 5 are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements have a substantially cylindrical shape. The diameter of the upstream filter element 4 b matches the diameter of the aerosol-forming substrate 2 bb. The diameter of the terminal filter element 5 b is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 b and the wrapping layer 3 b. The upstream filter element 4 b is slightly shorter in axial length than the terminal filter element 5 b at an axial length of 10 mm compared to 12 mm for the terminal filter element 5 b.

The cooling element 6 b has a substantially cylindrical form and is longer than each of the two filter elements 4 b, 5 having an axial length of around 14 mm. The cooling element 6 b comprises a fibrous mass (formed of viscose fibres) that is formed into the substantially cylindrical shape. Although not apparent from the figure, a plurality of phase change beads are distributed evenly within the fibrous mass. Each phase change bead is in the form of a spherical bead comprising a glass outer shell and a core of isocane (i.e., the phase change material). Outlast® Viscose Fibre (e.g., 7.0 dtex) may be used to form the cooling element 6 b.

Each filter element 4 b, 5 b is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter is slightly larger than the diameter of the bore in the terminal filter having a diameter of 3 mm compared to 2 mm for the terminal filter element 5 b.

The cooling element 6 b and the upstream filter element 4 b are circumscribed by the wrapping layer 3 b.

The terminal filter element 5 b is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7 b. The tipping layer 7 b encircles the terminal filter element 5 b and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6 b.

FIG. 9 shows a second embodiment of a consumable 1 b′ which is the same as that shown in FIG. 8 except that the terminal filter element 5 b is a solid filter element and comprises a crushable capsule 8 b (crush-ball) having a shell wall containing a liquid menthol or cherry or vanilla flavourant. The capsule 8 b is spherical and has a diameter of 3.5 mm. It is positioned within the axial centre of the terminal filter element 5 b.

FIG. 10 shows a third embodiment of a consumable 1 b″ which is the same as the first embodiment except that the wrapping layer 3 b does not completely circumscribe the cooling element 6 b such that there is an annular gap between the tipping layer 7 b and the cooling element 6 b downstream of the end of the wrapping layer 3 b.

FIG. 11 shows the first embodiment inserted into an HNB device 10 b comprising a rod-shaped heating element 20 b. The heating element 20 b projects into a cavity 11 b within the main body 12 b of the device.

The consumable 1 b is inserted into the cavity 11 b of the main body 12 b of the device 10 b such that the heating rod 20 b penetrates the aerosol-forming substrate 2 b. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 b is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5 b.

As the vapour cools within the upstream filter element 4 b and the cardboard tube spacer 6 b, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Fourth Mode of the Disclosure

As shown in FIG. 12, a HNB consumable 1 c comprises an aerosol-forming substrate 2 c at the upstream end of the consumable 1 c.

The aerosol-forming substrate 2 c comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2 c comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate 2 c further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 c is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2 c is circumscribed by a paper wrapping layer 3 c.

The consumable 1 c comprises an upstream filter element 4 c and a downstream (terminal) filter element 5 c. The two filter elements 4 c, 5 c and spaced by a cardboard spacer tube 6 c. Both filter elements 4 c, 5 c are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown). The density of the cellulose acetate tow is greater in the terminal filter element 5 c.

Both filter elements 4 c, 5 c have a substantially cylindrical shape. The diameter of the upstream filter 4 c matches the diameter of the aerosol-forming substrate 2 c. The diameter of the terminal filter element 5 c is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 c and the wrapping layer 3 c. The upstream filter element 4 c is slightly shorter in axial length than the terminal filter element 5 c at an axial length of 10 mm compared to 12 mm for the terminal filter element 5 c.

The cardboard tube spacer 6 c is longer than each of the two filter portions having an axial length of around 14 mm.

Each filter element 4 c, 5 c is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter 4 c is slightly larger than the diameter of the bore in the terminal filter 5 c having a diameter of 3 mm compared to 2 mm for the terminal filter element 5 c.

The cardboard spacer tube 6 c and the upstream filter portion 4 c are circumscribed by the wrapping layer 3 c.

The terminal filter element 5 c is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7 c. The tipping layer 7 c encircles the terminal filter portion and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6 c.

FIG. 13 shows a second embodiment of a consumable 1 c′ which is the same as the first embodiment except that the wrapping layer 3 c does not completely circumscribe the cardboard spacer tube 6 c such that there is an annular gap 9 c between the tipping layer 7 c and the cardboard spacer tube 6 c downstream of the end of the wrapping layer 3 c.

FIG. 14 shows the first embodiment inserted into an HNB device 10 c comprising a rod-shaped heating element (not shown). The heating element projects into a cavity 11 c within the main body 12 c of the device.

The consumable 1 c is inserted into the cavity 11 c of the main body 12 c of the device 10 c such that the heating rod penetrates the aerosol-forming substrate 2 c. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 c is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter portion 5 c.

As the vapour cools within the upstream filter element 4 c and the cardboard spacer tube 6 c, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Fifth Mode of the Present Disclosure

As shown in FIG. 15, the HNB consumable 1 d comprises an aerosol-forming substrate 2 d at the upstream end of the consumable 1 d.

The aerosol-forming substrate 2 d comprises a first, upstream portion 13 d of reconstituted tobacco spaced from a second, downstream portion 14 d of reconstituted tobacco by a cavity 15 d.

The cavity 15 d is filled with granules/chips/pellets of extruded tobacco 16 d.

The aerosol-forming substrate 2 d is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG).

The aerosol-forming substrate 2 d is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and each of the two portions 13 d, 14 d of reconstituted tobacco has an axial length of around 7 mm whilst the cavity 15 d has an axial length of around 6 mm.

The aerosol-forming substrate 2 d is circumscribed by a paper wrapping layer 3 d.

The consumable 1 d comprises an upstream filter element 4 d and a downstream (terminal) filter element 5 d. The two filter elements 4 d, 5 d and spaced by a cardboard spacer tube 6 d. Both filter elements 4 d, 5 d are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 4 d, 5 d have a substantially cylindrical shape. The diameter of the upstream filter 4 d matches the diameter of the aerosol-forming substrate 2 d. The diameter of the terminal filter element 5 d is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 d and the wrapping layer 3 d. The upstream filter element 4 d is slightly shorter in axial length than the terminal filter element 5 d at an axial length of 10 mm compared to 12 mm for the terminal filter element 5 d.

The cardboard tube spacer 6 d is longer than each of the two filter portions having an axial length of around 14 mm.

Each filter element 4 d, 5 d is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter 4 d is slightly larger than the diameter of the bore in the terminal filter 5 d having a diameter of 3 mm compared to 2 mm for the terminal filter element 5 d.

The cardboard spacer tube 6 d and the upstream filter portion 4 d are circumscribed by the wrapping layer 3 d.

The terminal filter element 5 d is joined to the upstream elements forming the consumable 1 d by a circumscribing paper tipping layer 7 d. The tipping layer 7 d encircles the terminal filter portion 5 d and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6 d.

FIG. 16 shows a second embodiment of a consumable 1 d′ which is the same as that shown in FIG. 15 except that the cavity 15 d houses an additive carrier 17 d which is a crushable capsule (crush-ball) having a shell wall containing polypropylene glycol or vegetable glycerine.

The terminal filter element 5 d comprises a further crushable capsule 8 d (crush-ball) having a shell wall containing a liquid menthol or cherry or vanilla flavourant. The capsule 8 d is spherical and has a diameter of 3.5 mm. It is positioned within the axial centre of the terminal filter portion 5 d. In other embodiments (not shown), the capsule 8 d can be omitted.

Furthermore, the capsule could be included in the terminal filter portion 5 d of the FIG. 15 embodiment.

FIG. 17 shows a third embodiment of a consumable 1 d″ which is the same as the first embodiment of FIG. 15 except that the wrapping layer 3 d does not completely circumscribe the cardboard spacer tube 6 d such that there is an annular gap 9 d between the tipping layer 7 d and the cardboard spacer tube 6 d downstream of the end of the wrapping layer 3 d. In the FIG. 17 embodiment, the extruded tobacco 16 d in the cavity 15 d could be replaced with the crushable capsule 17 d of the FIG. 16 embodiment and/or the crushable capsule 8 d of the FIG. 16 may be included in the terminal filter portion 5 d.

FIG. 18 shows the first embodiment of FIG. 15 inserted into an HNB device 10 d comprising a rod-shaped heating element (not shown). The heating element projects into a cavity 11 d within the main body 12 d of the device 10 d.

The consumable 1 d may be inserted into the cavity 11 d of the main body 12 d of the device 10 d such that the heating rod penetrates the aerosol-forming substrate 2 d.

Heating of the reconstituted tobacco in the aerosol-forming substrate 2 d is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter portion 5 d. The additive carrier 17 d and/or the crushable capsule 8 d can be ruptured by pressure to modify the flavour and/or amount of visible vapour during smoking of the consumable.

As the vapour cools within the upstream filter element 4 d and the cardboard spacer tube 6 d, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Sixth Mode of the Present Disclosure

As shown in FIG. 19, the HNB consumable 1 e comprises an aerosol-forming substrate 2 e at the upstream end of the consumable 1 e.

The aerosol-forming substrate 2 e comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2 e comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate 2 e further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 e is formed in a substantially cylindrical shape such that the consumable 1 e resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2 e is circumscribed by a paper wrapping layer 3 e.

The consumable 1 e comprises an upstream filter element 4 e and a downstream (terminal) filter element 5 e. The two filter elements 4 e, 5 e and spaced by a cardboard tube spacer 6 e. Both filter elements 4 e, 5 e are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 4 e, 5 e have a substantially cylindrical shape. The diameter of the upstream filter element 4 e matches the diameter of the aerosol-forming substrate 2 e. The diameter of the terminal filter element 5 e is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 e and the wrapping layer 3 e. The upstream filter element 4 e is slightly shorter in axial length than the terminal filter element 5 e at an axial length of 10 mm compared to 12 mm for the terminal filter element 5 e.

The cardboard tube spacer 6 e is longer than each of the two filter elements 4 e, 5 e having an axial length of around 14 mm.

Each filter element 4 e, 5 e is a hollow bore filter element with a hollow, longitudinally extending bore 7 e, 8 e. Although not immediately apparent from the figure, the bore 7 e of the upstream filter element 4 e has a generally circular transverse cross-section, whilst the bore 8 e of the terminal filter element 5 e has a non-circular transverse cross-section. This non-circular bore 8 e, will be described in more detail with reference to FIGS. 23A and 23B.

The cardboard tube spacer 6 e and the upstream filter element 4 e are circumscribed by the wrapping layer 3 e.

The terminal filter element 5 e is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 9 e. The tipping layer 9 e encircles the terminal filter element 5 e and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6 e.

FIG. 20 shows a second embodiment of a consumable 1 e′ which is the same as that shown in FIG. 19 except that the upstream filter element 4 e is a solid filter element and comprises a crushable capsule 10 e (crush-ball) having a shell wall containing a liquid menthol or cherry or vanilla flavourant. The capsule 10 e is spherical and has a diameter of 3.5 mm. It is positioned within the axial centre of the upstream filter element 4 e.

FIG. 21 shows a third embodiment of a consumable 1 e″ which is the same as the first embodiment except that the wrapping layer 3 e does not completely circumscribe the cardboard tube spacer 6 e such that there is an annular gap 11 e between the tipping layer 9 e and the cardboard tube spacer 6 e downstream of the end of the wrapping layer 3 e.

FIG. 22 shows the first embodiment inserted into an HNB device 12 e comprising a rod-shaped heating element 20 e. The heating element 20 e projects into a cavity 13 e within the main body 14 e of the device 12 e.

The consumable 1 e is inserted into the cavity 13 e of the main body 14 e of the device 12 e such that the heating rod 20 e penetrates the aerosol-forming substrate 2 e. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 e is effected by powering the heating element 20 e (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5 e.

As the vapour cools within the upstream filter element 4 e and the cardboard tube spacer 6 e, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

FIG. 23A is a perspective view of the first embodiment of the consumable 1 e of FIG. 19, with a portion of the wrapping layer 3 e and tipping paper 9 e cut away (i.e., for the purpose of showing the internal structure). FIG. 23B is an end view of the first embodiment. As is apparent from these figures, the bore 8 e of the terminal filter element 5 e has a transverse cross-section that has a central portion 15 e and a plurality of lobes 16 e extending outwardly from the central portion 15 e (i.e., so as to define a generally asterisk-shaped cross-section).

FIG. 24 shows a further embodiment of a terminal filter 5 e′. This is the same as the previously described embodiments, except that the bore 8 e′ of the terminal filter 5 e′ comprises a heart-shaped transverse cross-section.

The embodiment of the terminal filter 5 e″ shown in FIG. 25 comprises three bores 8 e″. Each of the three bores 8 e″ comprises a transverse cross-section that is triangular in shape.

FIG. 26 shows an embodiment of a terminal filter 5 e′″ that comprises four bores 8 e′″, 8 e″″. In particular, the terminal filter 5 e′″ comprises two bores 8 e′″ that each have a transverse cross-section that is star-shaped, and two bores 8 e″″ that each have a transverse cross-section that is square-shaped.

Seventh Mode of the Disclosure

As shown in FIG. 27, the HNB consumable 1 f comprises an aerosol-forming substrate 2 f at the upstream end of the consumable 1 f.

The aerosol-forming substrate 2 f comprises a first, axially upstream rod portion 13 f formed of reconstituted tobacco (e.g., gathered strips/shreds of reconstituted tobacco sheet) which is axially adjacent a second, downstream rod portion 14 f formed of an extruded tobacco rod. In other embodiments, the rod-shaped extrudate may be replaced with extruded tobacco granules/pellets/chips formed into a rod-shaped.

The upstream portion 13 f is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The upstream portion 13 f further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 f is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and each of the two rod portions 13 f, 14 f of reconstituted tobacco has an axial length of around 7 mm.

The aerosol-forming substrate 2 f is circumscribed by a paper wrapping layer 3 f.

The consumable 1 f comprises an upstream filter element 4 f and a downstream (terminal) filter element 5 f. The two filter elements 4 f, 5 f and spaced by a cardboard spacer tube 6 f. Both filter elements 4 f, 5 f are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 4 f, 5 f have a substantially cylindrical shape. The diameter of the upstream filter 4 f matches the diameter of the aerosol-forming substrate 2 f. The diameter of the terminal filter element 5 f is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 f and the wrapping layer 3 f. The upstream filter element 4 f is slightly shorter in axial length than the terminal filter element 5 f at an axial length of 10 mm compared to 12 mm for the terminal filter element 5 f.

The cardboard tube spacer 6 f is longer than each of the two filter portions 4 f, 5 f having an axial length of around 14 mm.

Each filter element 4 f, 5 f is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter 4 f is slightly larger than the diameter of the bore in the terminal filter 5 f having a diameter of 3 mm compared to 2 mm for the terminal filter element 5 f.

The cardboard spacer tube 6 f and the upstream filter portion 4 f are circumscribed by the wrapping layer 3 f.

The terminal filter element 5 f is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7 f. The tipping layer 7 f encircles the terminal filter portion 5 f and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6 f.

FIG. 28 shows a second embodiment of a consumable 1 f′ which is the same as that shown in FIG. 27 except that the reconstituted tobacco is provided as a radially inner rod 13 f′ and the extruded tobacco is provided as a radially outer tube 14 f.

The terminal filter element 5 f comprises a crushable capsule 8 f (crush-ball) having a shell wall containing a liquid menthol or cherry or vanilla flavourant. The capsule 8 f is spherical and has a diameter of 3.5 mm. It is positioned within the axial centre of the terminal filter portion 5 f. In other embodiments (not shown), the capsule 8 f can be omitted.

Furthermore, the capsule 8 f could be included in the terminal filter portion 5 f of the FIG. 27 embodiment.

FIG. 29 shows a third embodiment of a consumable 1 f″ which is the same as the first embodiment except that the wrapping layer 3 f does not completely circumscribe the cardboard spacer tube 6 f such that there is an annular gap 9 f between the tipping layer 7 f and the cardboard spacer tube 6 f downstream of the end of the wrapping layer 3 f. Furthermore, the second, downstream portion 14 f′ is provided as chips/granules/pellets of extruded tobacco. In the FIG. 29 embodiment, the axially segregated rod portions 13 f, 14 r could be replaced with the radially segregated rod/tube portions 13 r, 14 f of FIG. 28 or the chips/granules/pellets of extruded tobacco in the second, downstream portion 14 f could be replaced with an extruded tobacco rod.

FIG. 30 shows the first embodiment inserted into an HNB device 10 f comprising a rod-shaped heating element (not shown). The heating element projects into a cavity 11 f within the main body 12 f of the device.

The consumable 1 f is inserted into the cavity 11 f of the main body 12 f of the device 10 f such that the heating rod penetrates the aerosol-forming substrate 2 f. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 f is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter portion 5 f.

FIG. 31 shows the first embodiment inserted into a second HNB device comprising two axially spaced and separately controllable tubular heating elements 15 f, 15 r which surround the cavity 11 f. In this way the rod portions 13 f, 14 f can be heated at different rates/temperatures.

As the vapour cools within the upstream filter element 4 f and the cardboard spacer tube 6 f, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Eighth Mode of the Disclosure

As shown in FIG. 32, the HNB consumable 1 g comprises an aerosol-forming substrate 2 g at the upstream end of the consumable 1 g.

The aerosol-forming substrate 2 g comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2 g comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 g is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2 g is circumscribed by a paper wrapping layer 3 g.

The consumable 1 g comprises an upstream filter element 4 g and a downstream (terminal) filter element 5. The two filter elements 4 g, 5 g and spaced by a cardboard tube spacer 6 g. The upstream filter element 4 g is formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

The terminal filter element 5 g comprise an upstream filter portion 5 g′ in the form of a hollow bore filter element and a downstream filter portion 5 g″ in the form of a solid filter element. The upstream 5 g′ and downstream 5 g″ filter portion are located axially adjacent to one another and are joined by a paper plug wrap (not shown). Both the upstream 5 g′ and downstream 5 g″ filter portions are formed of cellulose acetate tow. Although not apparent, the downstream filter portion 5 g″ comprises an additive in the form of a menthol flavourant. The axial length of each of the filter portions 5 g′, 5 g″ is around 6 mm, such that the axial length of the terminal filter element 5 g is around 12 mm.

Both filter elements 4 g, 5 g have a substantially cylindrical shape. The diameter of the upstream filter element 4 g matches the diameter of the aerosol-forming substrate 2 g. The diameter of the terminal filter element 5 g is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 g and the wrapping layer 3 g. The upstream filter element 4 g is slightly shorter in axial length than the terminal filter element 5 g at an axial length of 10 mm.

The cardboard tube spacer 6 g is longer than each of the two filter elements 4 g, 5 g having an axial length of around 14 mm.

The upstream filter element 4 g is a hollow bore filter element (like the upstream portion 5 g′ of the terminal filter element 5 g) with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter element 4 g is slightly larger than the diameter of the bore in the upstream filter portion 5 g′ of the terminal filter element 5 g having a diameter of 3 mm compared to 2 mm for the upstream filter portion 5 g′ of the terminal filter element 5 g.

The cardboard tube spacer 6 g and the upstream filter element 4 g are circumscribed by the wrapping layer 3 g.

The terminal filter element 5 g is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7 g tipping layer 7 g (i.e., circumscribing the plug wrap joining the filter portions 5 g′, 5 b). The tipping layer 7 g encircles the terminal filter element 5 g and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6 g.

FIG. 33 shows a second embodiment of a consumable 1 g′ which is the same as that shown in FIG. 32 except that the downstream filter portion 5 g″ of the terminal filter element 5 g comprises a crushable capsule 8 g (crush-ball) having a shell wall containing a liquid menthol or cherry or vanilla flavourant. The capsule 8 g is spherical and has a diameter of 3.5 mm. It is positioned within the axial centre of the downstream filter portion 5 g″ of the terminal filter element 5 g.

FIG. 34 shows a third embodiment of a consumable 1 g″ which is the same as the first embodiment except that the upstream filter portion 5 g′ is a solid filter element and the downstream filter portion 5 g″ is a hollow bore filter element (i.e., the arrangement is reversed from the previously described embodiments). Furthermore, the wrapping layer 3 g does not completely circumscribe the cardboard tube spacer 6 g such that there is an annular gap 9 g between the tipping layer 7 g and the cardboard tube spacer 6 g downstream of the end of the wrapping layer 3 g.

FIG. 35 shows the first embodiment inserted into an HNB device 11 g comprising a rod-shaped heating element 20 g. The heating element 20 g projects into a cavity 12 g within the main body 13 g of the device.

The consumable 1 g is inserted into the cavity 12 g of the main body 13 g of the device 11 g such that the heating rod 20 g penetrates the aerosol-forming substrate 2 g. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 g is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5 g.

As the vapour cools within the upstream filter element 4 g and the cardboard tube spacer 6 g, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Ninth Mode of the Disclosure

As shown in FIG. 36, the HNB consumable 1 h comprises an aerosol-forming substrate 2 h at the upstream end of the consumable 1 h.

The aerosol-forming substrate 2 h comprises a rod-shaped extrudate of tobacco and is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG).

The aerosol-forming substrate 2 h is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm. The extrudate comprises an axial bore 13 h which has its axial upstream end at the axial upstream end of the aerosol-forming substrate 2 h. The axial bore 13 h extends the entire length of the extrudate and thus has an axial length of 12 mm. It has a bore diameter of around 2 mm.

The aerosol-forming substrate 2 h is circumscribed by a paper wrapping layer 3 h.

The consumable 1 h comprises an upstream filter element 4 h and a downstream (terminal) filter element 5 h. The two filter elements 4 h, 5 h and spaced by a cardboard spacer tube 6 h. Both filter elements 4 h, 5 h are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 4 h, 5 h have a substantially cylindrical shape. The diameter of the upstream filter 4 h matches the diameter of the aerosol-forming substrate 2 h. The diameter of the terminal filter element 5 h is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 h and the wrapping layer 3 h. The upstream filter element 4 h is slightly shorter in axial length than the terminal filter element 5 h at an axial length of 10 mm compared to 12 mm for the terminal filter element 5 h.

The cardboard tube spacer 6 h is longer than each of the two filter portions 4 h, 5 h having an axial length of around 14 mm.

Each filter element 4 h, 5 h is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter 4 h is slightly larger than the diameter of the bore in the terminal filter 5 h having a diameter of 3 mm compared to 2 mm for the terminal filter element 5 h.

The cardboard spacer tube 6 h and the upstream filter portion 4 h are circumscribed by the wrapping layer 3 h.

The terminal filter element 5 h is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7 h. The tipping layer 7 h encircles the terminal filter portion and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6 h.

FIG. 37 shows a second embodiment of a consumable 1 h′ which is the same as that shown in FIG. 36 except that the terminal filter element 5 h is a solid filter element and comprises a crushable capsule 8 h (crush-ball) having a shell wall containing a liquid menthol or cherry or vanilla flavourant. The capsule 8 h is spherical and has a diameter of 3.5 mm. It is positioned within the axial centre of the terminal filter portion 5 h. The capsule 8 h may be omitted from the FIG. 37 embodiment and may be included in the FIG. 36 embodiment. In the second embodiment, the axial bore 13 h does not extend the entire length of the substrate 2 h.

FIG. 38 shows a third embodiment of a consumable 1 h″ which is the same as the first embodiment except that the wrapping layer 3 h does not completely circumscribe the cardboard spacer tube 6 h such that there is an annular gap 9 h between the tipping layer 7 h and the cardboard spacer tube 6 h downstream of the end of the wrapping layer 3 h. Furthermore, the substrate 2 h does not include an axial bore.

FIG. 39 shows the first embodiment inserted into an HNB device 10 h comprising a rod-shaped heating element 20 h. The heating element projects into a cavity 11 h within the main body 12 h of the device.

The consumable 1 h is inserted into the cavity 11 h of the main body 12 h of the device 10 h such that the heating rod 20 h is received in the axial bore 13 h of the aerosol-forming substrate 2 h. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 h is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter portion 5 h.

As the vapour cools within the upstream filter element 4 h and the cardboard spacer tube 6 h, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Tenth Mode of the Disclosure

As shown in FIG. 40, the HNB consumable 1 i comprises an aerosol-forming substrate 2 i at the upstream end of the consumable 1 i.

The aerosol-forming substrate 2 i comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2 i comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate 2 i further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 i is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2 i is circumscribed by a paper wrapping layer 3 i.

The consumable 1 i comprises an upstream filter element 4 i and a downstream (terminal) filter element 5 i. The two filter elements 4 i, 5 i are spaced by a cardboard tube spacer 6 i. Both filter elements 4 i, 5 i are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 4 i, 5 i have a substantially cylindrical shape. The diameter of the upstream filter 4 i matches the diameter of the aerosol-forming substrate 2 i. The diameter of the terminal filter element 5 i is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 i and the wrapping layer 3 i. The upstream filter element 4 i is slightly shorter in axial length than the terminal filter element 5 i at an axial length of 10 mm compared to 12 mm for the terminal filter element 5 i.

The terminal filter element 5 i is made up of two axially abutting filter portions 5 i′ and Si“. The terminal portion 5 i′ is a solid cellulose acetate tow filter portion. The upstream filter portion 5 i” of the terminal filter element 5 i is a cellulose acetate tow filter portion defining a hollow, longitudinally (axially) extending bore.

The cardboard tube spacer 6 i is longer than each of the two filter elements 4 i, 5 i having an axial length of around 14 mm.

The diameter of the bore in the filter portion 4 i is slightly larger than the diameter of the bore in the portion 5 i′ of the terminal filter element 5 i having a diameter of 3 mm compared to 2 mm for the terminal filter element portion 5 i″.

The cardboard tube spacer 6 i and the upstream filter element 4 i are circumscribed by the wrapping layer 3 i.

The terminal filter element 5 i is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7 i. The tipping layer 7 i encircles the terminal filter element 5 i and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6 i.

A region of weakness 7 i′ is provided in the paper tipping layer 7 i, consisting of an annular array of perforations in the paper tipping layer 7 i which circumscribes the terminal filter element 5 i. The region of weakness 7 i′ directly overlies the junction between the two filter portions 5 i′ and 5 i″.

Either before or during use, should the user require an increased intensity (lower level of filtration), force may be applied to the terminal filter portion 5 i′ to break the region of weakness 7 i′ and separate the two filter portions 5 i′, 5 i″ of the terminal filter element 5 i. The terminal filter portion 5 i′ may then be disposed of, for example into a waste bin or recycling.

FIG. 41 shows the consumable of FIG. 40 after removal of the terminal portion 5 i′ of the terminal filter element 5 i. The terminal filter element 55 now consists only of the hollow bore filter portion 5 i′ which provides a reduced level of filtration relative to the longer terminal filter element 5 i of FIG. 40. The reduced level of filtration is provided by both the reduced overall axial length of the terminal filter element 5 i, and further reduction is provided by the fact that portion 5 i″ includes the hollow bore. In alternative embodiments, filter portion 5 i″ may be a solid filter and the reduction in level of filtration will be provided simply by the reduction in overall axial length of the terminal filter element after breakage.

FIG. 42 shows a second embodiment of a consumable 1 i′ which is the same as that shown in FIG. 40 except that both filter portions 5 i′, 5 i″ of the terminal filter element 5 i are solid filter portions and the upstream filter portion 5 i″ comprises a crushable capsule 8 i (crush-ball) having a shell wall containing a liquid menthol or cherry or vanilla flavourant. The capsule 8 i is spherical and has a diameter of 3.5 mm. It is positioned within the axial centre of the upstream filter portion 5 i″.

During use the user may apply pressure to the capsule 8 i to break the capsule and release the flavourant. The flavour can be provided whether or not the user decides to break off the terminal filter portion 5 i′ due to the location of the capsule within the other filter portion 5 i″.

FIG. 43 shows a third embodiment of a consumable 1 i″ which is the same as the first embodiment except that the wrapping layer 3 i does not completely circumscribe the cardboard tube spacer 6 i such that there is an annular gap 9 i between the tipping layer 7 i and the cardboard tube spacer 6 i downstream of the end of the wrapping layer 3 i.

FIG. 44 shows the first embodiment inserted into an HNB device 10 i comprising a rod-shaped heating element 20 i. The heating element 20 i projects into a cavity 11 i within the main body 12 i of the device 10 i.

The consumable 1 i is inserted into the cavity 11 i of the main body 12 i of the device 10 i such that the heating rod 20 i penetrates the aerosol-forming substrate 2 i. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 i is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5 i.

As the vapour cools within the upstream filter element 4 i and the cardboard tube spacer 6 i, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Eleventh Mode of the Disclosure

As shown in FIG. 45, the HNB consumable 1 j comprises an aerosol-forming substrate 2 j at the upstream end of the consumable 1 j.

The aerosol-forming substrate 2 j comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2 j comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 j is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2 j is circumscribed by a paper wrapping layer 3 j.

The consumable 1 j comprises an upstream filter element 4 j and a downstream (terminal) filter element 5 j. The two filter elements 4 j, 5 j and spaced by a cardboard tube spacer 6 j. Both filter elements 4 j, 5 j are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 4 j, 5 j have a substantially cylindrical shape. The diameter of the upstream filter 4 j matches the diameter of the aerosol-forming substrate 2 j. The diameter of the terminal filter element 5 j is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 j and the wrapping layer 3 j. The upstream filter element 4 j is shorter in axial length than the terminal filter element 5 j at an axial length of 10 mm compared to 12 mm for the terminal filter element 5 j.

The cardboard tube spacer 6 j is longer than each of the two filter elements 4 j, 5 j having an axial length of around 14 mm.

Each filter element 4 j, 5 j is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter element 4 j is slightly larger than the diameter of the bore in the terminal filter element 5 j having a diameter of 3 mm compared to 2 mm for the terminal filter element 5 j. The porosity of the upstream filter element 4 j is greater than the porosity of the terminal filter element 5 j.

The cardboard tube spacer 6 j and the upstream filter element 4 j are circumscribed by the wrapping layer 3 j.

The terminal filter element 5 j is joined to the upstream elements forming the consumable 1 j by a circumscribing paper tipping layer 7 j. The tipping layer 7 j encircles the terminal filter element 5 j and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6 j.

FIG. 46 shows a third embodiment of a consumable 1 j″ which is the same as the first embodiment except that the wrapping layer 3 j does not completely circumscribe the cardboard tube spacer 6 j such that there is an annular gap 9 j between the tipping layer 7 j and the cardboard tube spacer 6 j downstream of the end of the wrapping layer 3 j.

FIG. 47 shows the first embodiment inserted into an HNB device 10 j comprising a rod-shaped heating element 20 j. The heating element 20 j projects into a cavity 11 j within the main body 12 j of the device.

The consumable 1 j is inserted into the cavity 11 j of the main body 12 j of the device 10 j such that the heating rod 20 j penetrates the aerosol-forming substrate 2 j. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 j is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5 j.

As the vapour cools within the upstream filter element 4 j and the cardboard tube spacer 6 j, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Providing a shorter upstream filter element 4 j results in a greater concentration of nicotine at the terminal filter element 5 j because there is less condensation of the nicotine on the upstream filter element 4 j. The vapour containing an increased concentration of nicotine vapour can then pass unimpeded through the hollow bore filter of the terminal filter element 5 j and the extended length (relative to the upstream filter element 4 j) provide an increased opportunity for mixing of the components (e.g., nicotine and humectant) within the bore of the terminal filter element 5 j. The increased density of the terminal filter element 5 j also helps increase flow and therefore mixing of the aerosol/vapour within the bore of the terminal filter element 5 j.

Twelfth Mode of the Disclosure

As shown in FIG. 48, the HNB consumable 1 k comprises an aerosol-forming substrate 2 k at the upstream end of the consumable 1 k.

The aerosol-forming substrate 2 k comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2 k comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate 2 k further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 k is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2 k is circumscribed by a paper wrapping layer 3 k.

The consumable 1 k comprises an upstream filter element 4 k and a downstream (terminal) filter element 5 k. The two filter elements 4 k, 5 k and spaced by a cardboard tube spacer 6 k. Both filter elements 4 k, 5 k are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 4 k, 5 k have a substantially cylindrical shape. The diameter of the upstream filter 4 k matches the diameter of the aerosol-forming substrate 2 k. The diameter of the terminal filter element 5 k is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 k and the wrapping layer 3 k. The upstream filter element 4 k is shorter in axial length than the terminal filter element 5 k at an axial length of 10 mm compared to 12 mm for the terminal filter element 5 k.

The cardboard tube spacer 6 k is longer than each of the two filter elements 4 k, 5 k having an axial length of around 14 mm.

Each filter element 4 k, 5 k is a hollow bore filter element with a respective hollow, longitudinally extending bore 4 k′, 5 k′. The diameter of the bore 4 k′ in the upstream filter element 4 k is larger than the diameter of the bore 5 k′ in the terminal filter element 5 k having a diameter of 3 mm compared to 2 mm for the terminal filter element 5 k. The porosity of the upstream filter element 4 k is greater than the porosity of the terminal filter element 5 k.

The cardboard tube spacer 6 k and the upstream filter element 4 k are circumscribed by the wrapping layer 3 k.

The terminal filter element 5 k is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7 k. The tipping layer 7 k encircles the terminal filter element 5 k and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6 k.

FIG. 49 shows a third embodiment of a consumable 1 k″ which is the same as the first embodiment except that the wrapping layer 3 k does not completely circumscribe the cardboard tube spacer 6 k such that there is an annular gap 9 k between the tipping layer 7 k and the cardboard tube spacer 6 k downstream of the end of the wrapping layer 3 k.

FIG. 50 shows the first embodiment inserted into an HNB device 10 k comprising a rod-shaped heating element 20 k. The heating element 20 k projects into a cavity 11 k within the main body 12 k of the device.

The consumable 1 k is inserted into the cavity 11 k of the main body 12 k of the device 10 k such that the heating rod 20 k penetrates the aerosol-forming substrate 2 k. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 k is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5 k.

As the vapour cools within the upstream filter element 4 k and the cardboard tube spacer 6 k, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

By providing a terminal filter element 5 k with a bore 5 k′ having a reduced bore diameter (compared to the bore 4 k′ in the upstream hollow bore filter element 4 k), a greater mixing effect is achieved within the terminal hollow bore filter element 5 k as all of the components of the vapour/aerosol are forced to co-locate within the more restricted hollow bore 5 k′. The increased length of the terminal hollow bore filter 5 k also provides for good mixing (within the bore) of the vapour components.

The increased density of the terminal filter element 5 k also helps increase flow and therefore mixing of the aerosol/vapour within the bore 5 k′ of the terminal filter element 5 k.

Thirteenth Mode of the Disclosure

As shown in FIG. 51, the HNB consumable 1 m comprises an aerosol-forming substrate 2 m at the upstream end of the consumable 1 m.

The aerosol-forming substrate 2 m comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2 m comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 m is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2 m is circumscribed by a paper wrapping layer 3 m.

The consumable 1 m comprises an upstream filter element 4 m and a downstream (terminal) filter element 5 m. The two filter elements 4 m, 5 m and spaced by a cardboard tube spacer 6 m. Both filter elements 4 m, 5 m are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 4 m, 5 m have a substantially cylindrical shape. The diameter of the upstream filter 4 m matches the diameter of the aerosol-forming substrate 2 m. The diameter of the terminal filter element 5 m is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 m and the wrapping layer 3 m. The upstream filter element 4 m is shorter in axial length than the terminal filter element 5 m at an axial length of 10 mm compared to 12 mm for the terminal filter element 5 m.

The cardboard tube spacer 6 m is longer than each of the two filter elements 4 m, 5 m having an axial length of around 14 mm.

Each filter element 4 m, 5 m is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter element 4 m is slightly larger than the diameter of the bore in the terminal filter element 5 m having a diameter of 3 mm compared to 2 mm for the terminal filter element 5 m. The porosity of the upstream filter element 4 m is greater than the porosity of the terminal filter element 5 m.

The cardboard tube spacer 6 m and the upstream filter element 4 m are circumscribed by the wrapping layer 3 m.

The terminal filter element 5 m is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7 m. The tipping layer 7 m encircles the terminal filter element 5 m and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6 m.

The terminal filter element 5 m has a greater hardness (95%) than the upstream filter element 4 m hardness (90%).

FIG. 52 shows a second embodiment of a consumable 1 m′ which is the same as the first embodiment except that the wrapping layer 3 m does not completely circumscribe the cardboard tube spacer 6 m such that there is an annular gap 9 m between the tipping layer 7 m and the cardboard tube spacer 6 m downstream of the end of the wrapping layer 3 m.

FIG. 53 shows the first embodiment inserted into an HNB device 10 m comprising a rod-shaped heating element 20 m. The heating element 20 m projects into a cavity 11 m within the main body 12 m of the device 10 m.

The consumable inn is inserted into the cavity 11 m of the main body 12 m of the device 10 m such that the heating rod 20 m penetrates the aerosol-forming substrate 2 m. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 m is effected by powering the heating element 20 m (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5 m.

As the vapour cools within the upstream filter element 4 m and the cardboard tube spacer 6 m, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Providing a harder terminal filter element 5 m than the upstream filter element 4 m increases the flow and mixing of the vapour/aerosol within the hollow bore of the terminal filter element 5 m. The increased hardness/reduced porosity of the terminal filter element 5 m forces the aerosol/vapour to enter the axial bore through the terminal filter element 5 m (since the passage through the body of the terminal filter element 5 m is impeded) and this forces the components within the vapour/aerosol to co-locate within the bore thus increasing mixing. Furthermore, the increased hardness of the terminal filter element 5 m may reduce the need for filter plasticisers at the downstream (mouth) end of the article. The less hard/less dense upstream filter element 4 m allows a greater passage of aerosol/vapour through the body of the upstream filer element thus filtering out harmful particulate matter prior to its delivery at the axial bore of the terminal filter element 5 m. Furthermore, the hardness of the two filter elements 4 m, 5 m can be used to tailor the RTD of the consumable 1 m.

Fourteenth Mode of the Disclosure

As shown in FIG. 54, the HNB consumable 1 n comprises an aerosol-forming substrate 2 n at the upstream end of the consumable 1 n.

The aerosol-forming substrate comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2 n comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 n is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2 n is circumscribed by a paper wrapping layer 3 n.

The consumable 1 n comprises an upstream filter element 4 n and a downstream (terminal) filter element 5 n. The two filter elements 4 n, 5 n and spaced by a cardboard tube spacer 6 n. Both filter elements 4 n, 5 n are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements have a substantially cylindrical shape. The diameter of the upstream filter 4 n matches the diameter of the aerosol-forming substrate 2 n. The diameter of the terminal filter element 5 n is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 n and the wrapping layer 3 n. The upstream filter element is slightly shorter in axial length than the terminal filter element at an axial length of 10 mm compared to 12 mm for the terminal filter element.

The cardboard tube spacer is longer than each of the two filter elements having an axial length of around 14 mm.

Both filter elements 4 n, 5 n are hollow bore filter elements with a hollow, longitudinally-extending axial bore. The diameter of the axial bore in the upstream filter 4 n is slightly larger than the diameter of the axial bore in the terminal filter element 5 n having a diameter of 3 mm compared to 2 mm for the terminal filter element.

The cardboard tube spacer 6 n and the upstream filter element 4 n are circumscribed by the wrapping layer 3 n.

The terminal filter element 5 n is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7 n. The tipping layer 7 n encircles the terminal filter element 5 n and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6 n.

A plurality of radial air flow paths are provided by a first circumferentially-extending row of ventilation holes 13′, 13″ and an axially spaced second circumferentially-extending row of ventilation holes 14′, 14″ in the wrapping layer 3 n which are circumferentially arranged around the aerosol-forming substrate 2 n.

FIG. 55 shows a second embodiment of a consumable 1 n′ which is the same as the first embodiment except that the upstream filter element 4 n′ is a solid filter element and incudes a crushball 8 n which contains a flavourant.

FIG. 56 shows a third embodiment of a consumable 1 n″ which is the same as the first embodiment except that the wrapping layer 3 n does not completely circumscribe the cardboard tube spacer 6 n such that there is an annular gap 9 n between the tipping layer 7 n and the cardboard tube spacer 6 n downstream of the end of the wrapping layer 3 n.

FIG. 57 shows the first embodiment inserted into an HNB device 10 n comprising a rod-shaped heating element 20 n. The heating element 20 n projects into a cavity 11 n within the main body 12 n of the device 10 n.

The consumable 1 n is inserted into the cavity 11 n of the main body 12 n of the device 10 n such that the heating rod 20 n penetrates the aerosol-forming substrate 2 n. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 n is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5 n.

As the vapour cools within the upstream filter element 4 n and the cardboard tube spacer 6 n, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Inhalation by the user also draws in air along the radial flow paths through the ventilation holes 13′, 13″, 14′, 14″. This air helps to vaporise the nicotine and humectants within the aerosol-forming substrate to increase the volume of vapour and the TPM.

Fifteenth Mode of the Disclosure

As shown in FIG. 58, the HNB consumable 1 p comprises an aerosol-forming substrate 2 p at the upstream end of the consumable 1 p.

The aerosol-forming substrate 2 p comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2 p comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 p is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2 p is circumscribed by a paper wrapping layer 3 p.

The consumable 1 p comprises an upstream filter element 4 p and a downstream (terminal) filter element 5 p. The two filter elements 4 p, 5 p are spaced by a cardboard spacer tube 6 p. Both filter elements 4 p, 5 p are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Terminal filter element 5 p comprises an upstream filter portion 5 p′ and a downstream filter portion 5 p″ that sandwiches adsorbent additive 14 p.

All filter elements/portions have a substantially cylindrical shape. The diameter of the upstream filter 4 p matches the diameter of the aerosol-forming substrate 2 p. The diameter of the terminal filter element 5 p/terminal filter portions 5 p′, 5 p″ is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 p and the wrapping layer 3 p. The upstream filter element 4 p is slightly shorter in axial length than the terminal filter element 5 p at an axial length of 10 mm compared to 12 mm for the terminal filter element 5 p.

The cardboard tube spacer 6 p is longer than each of the two filter elements 4 p, 5 p having an axial length of around 14 mm.

Upstream filter element 4 p, upstream filter portion 5 p′ and downstream filter portion 5 p″ (forming the terminal filter element 5 pp) are each a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter element 4 p is slightly larger than the diameter of the bore in the terminal filter element 5 p having a diameter of 3 mm compared to 2 mm for the terminal filter element 5 p.

The cardboard spacer tube 6 p and the upstream filter element 4 p are circumscribed by the wrapping layer 3 p.

The terminal filter element 5 p is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7 p. The tipping layer 7 p encircles the terminal filter portion and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6 p.

FIG. 59 shows a second embodiment of a consumable 1 p which is the same as that shown in FIG. 58 except that filter element 5 p is impregnated with additive adsorbent 14 p throughout its entirety. Furthermore, the terminal filter element 5 p is a solid filter element and comprises a crushable capsule 8 p (crush-ball) having a shell wall containing a liquid menthol or cherry or vanilla flavourant. The capsule 8 p is spherical and has a diameter of 3.5 mm. It is positioned within the axial centre of the terminal filter portion 5 p.

FIG. 60 shows a third embodiment of a consumable 1 p which is the same as the first embodiment except that filter element 5 p is impregnated with additive adsorbent 14 p in an axially central portion that accounts for just under a third of the volume of filter element 5 p. Furthermore, the wrapping layer 3 p does not completely circumscribe the cardboard spacer tube 6 p such that there is an annular gap 9 p between the tipping layer 7 p and the cardboard spacer tube 6 p downstream of the end of the wrapping layer 3 p.

FIG. 61 shows a fourth embodiment of the consumable 1 p inserted into an HNB device 10 p comprising a rod-shaped heating element 20 p. The fourth embodiment is the same as the first embodiment except that the additive adsorbent 14 p is in the form of pellets that are evenly distributed within the terminal filter element 5 p. The heating element projects into a cavity 11 p within the main body 12 p of the device 10 p.

The consumable 1 p is inserted into the cavity 11 p of the main body 12 p of the device 10 p such that the heating rod 20 p penetrates the aerosol-forming substrate 2 p. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 p is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter portion 5 p.

As the vapour cools within the upstream filter element 4 p and the cardboard spacer tube 6 p, it condenses to form an aerosol containing the volatile compounds for inhalation by the user. The absorbent additive 14 p within the terminal filter element 5 pp removes hazardous substances from the aerosol as it passes through the terminal filter element 5 p. In particular, the adsorbent additive 14 removes tobacco-specific nitrosamines (TSNAs) from the aerosol.

Turning now to consider FIG. 62, a fifth embodiment of a HNB consumable 1 p comprises an aerosol-forming substrate 2 p at the upstream end of the consumable 1 p.

The aerosol-forming substrate comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2 p comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 p is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2 p is circumscribed by a paper wrapping layer 3 p.

The consumable 1 p comprises an upstream filter element 4 p and a downstream (terminal) filter element 5 p.

The two filter elements 4 p, 5 are spaced by a cardboard tube spacer 6 p. Both filter elements 4 p, 5 are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements have a substantially cylindrical shape. The diameter of the upstream filter 4 p matches the diameter of the aerosol-forming substrate 2 p. The diameter of the terminal filter element 5 p is slightly larger and matches the combined diameter of the aerosol-forming substrate 2 p and the wrapping layer 3 p.

The upstream filter element is slightly shorter in axial length than the terminal filter element at an axial length of 10 mm compared to 12 mm for the terminal filter element. The cardboard tube spacer 6 p is longer than each of the two filter portions having an axial length of around 14 mm.

Each filter element 4 p, 5 p is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter is slightly larger than the diameter of the bore in the terminal filter having a diameter of 3 mm compared to 2 mm for the terminal filter element.

The terminal filter element 5 p is impregnated with water.

The cardboard tube spacer 6 p and the upstream filter portion 4 p are circumscribed by the wrapping layer 3 p.

The terminal filter element 5 p is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7 p. The tipping layer 7 p encircles the terminal filter portion and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6 p.

FIG. 63 shows a sixth embodiment of a consumable 1 p which is the same as that shown in FIG. 62 except that the terminal filter element 5 p is a solid filter element and comprises a crushable capsule 8 p (crush-ball) having a shell wall containing water. The capsule 8 p is spherical and has a diameter of 3.5 mm. It is positioned within the axial centre of the terminal filter portion 5 p.

FIG. 64 shows a seventh embodiment of a consumable 1 p which is the same as the fifth embodiment except that the upstream filter element 4 p is impregnated with water. Furthermore, the wrapping layer 3 p does not completely circumscribe the cardboard tube spacer 6 p such that there is an annular gap 9 p between the tipping layer 7 p and the cardboard tube spacer 6 p downstream of the end of the wrapping layer 3 p.

FIG. 65 shows the fifth embodiment inserted into an HNB device 10 p comprising a rod-shaped heating element 20 p. The heating element 20 p projects into a cavity 11 p within the main body 12 p of the device 10 p.

The consumable 1 p is inserted into the cavity 11 p of the main body 12 p of the device 10 p such that the heating rod 20 p penetrates the aerosol-forming substrate 2 p. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 p is effected by powering the heating element 20 p (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter portion 5 p.

As the vapour cools within the upstream filter element 4 p and the cardboard tube spacer 6 p, it condenses to form an aerosol containing the volatile compounds for inhalation by the user. The aerosol passes through the terminal filter element 5 p where TSNA compounds are absorbed by the water contained within the terminal filter element.

Sixteenth Mode of the Disclosure

As shown in FIG. 66, the HNB consumable 1 q comprises an aerosol-forming substrate 2 q at the upstream end of the consumable 1 q.

The aerosol-forming substrate 2 q comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2 q comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerine (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 2 q is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 2 q is circumscribed by a paper wrapping layer 3 q.

The consumable 1 q comprises an upstream filter element 4 q and a downstream (terminal) filter element 5 q. The two filter elements 4 q, 5 q and spaced by a cardboard tube spacer 6 q. Both filter elements 4 q, 5 q are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 4 q, 5 q have a substantially cylindrical shape. The diameter of the upstream filter 4 q matches the diameter of the aerosol-forming substrate 2 q. The upstream filter element 4 q is slightly shorter in axial length than the terminal filter element 5 q at an axial length of 10 mm compared to 12 mm for the terminal filter element 5 q.

The cardboard tube spacer 6 q is longer than each of the two filter elements 4 q, 5 q having an axial length of around 14 mm.

Each filter element 4 q, 5 q is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter 4 q is slightly larger than the diameter of the bore in the terminal filter 5 q having a diameter of 3 mm compared to 2 mm for the terminal filter element 5 q.

The cardboard tube spacer 6 q and the upstream filter element 4 q are circumscribed by the wrapping layer 3 q.

The terminal filter element 5 q has a corrugated outer surface comprising a series of longitudinally-extending channels 10 q. The terminal filter element 5 q is circumscribed by a paper sleeve 9 q which lies against the peaks of the corrugations on the outer surface of the terminal filter element 5 q but leaves the longitudinally-extending channels 10 q unimpeded.

The terminal filter element 5 q is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 7 q. The tipping layer 7 q encircles the terminal filter element 5 q (and the paper sleeve 9 q) and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 6 q.

FIG. 67 shows a second embodiment of a consumable 1 q′ which is the same as that shown in FIG. 66 except that the terminal filter element 5 q is a solid filter element and comprises a longitudinally-extending thread 8 q soaked with a liquid menthol or cherry or vanilla flavourant. It is positioned along the axial centre of the terminal filter element 5 q.

FIG. 68 shows an exploded view of the terminal filter element 5 q comprising its plug wrap 11 q which has corrugations matching those in the corrugated outer surface 12 q of the terminal filter element 5 q. The paper sleeve 9 q overlays the outer surface 12 q and plug wrap 11 q and rests against the peaks in the corrugations leaving the longitudinally-extending channels 10 q unimpeded. The tipping layer 7 q circumscribes the paper sleeve 9 q.

FIG. 69 shows the second embodiment inserted into an HNB device 10 q comprising a rod-shaped heating element 20 q. The heating element 20 q projects into a cavity 11 q within the main body 12 q of the device 10 q.

The consumable 1 q is inserted into the cavity 11 q of the main body 12 q of the device 10 q such that the heating rod 20 q penetrates the aerosol-forming substrate 2 q. Heating of the reconstituted tobacco in the aerosol-forming substrate 2 q is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapour and entrained within an airflow generated by inhalation by the user at the terminal filter element 5 q.

As the vapour cools within the upstream filter element 4 q and the cardboard tube spacer 6 q, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Some of the aerosol passes through the terminal filter element 5 q where it is flavoured by the flavourant-soaked thread 8 q. The remainder of the aerosol passes unimpeded through the longitudinal channels 10 q in the outer surface of the filter element 5 q thus increasing the visible vapour at the downstream axial end (mouth-end) of the consumable 1 q.

The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the scope of the invention.

For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.

Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

Throughout this specification, including the claims which follow, unless the context requires otherwise, the words “have”, “comprise”, and “include”, and variations such as “having”, “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means, for example, +/−10%.

The words “preferred” and “preferably” are used herein refer to embodiments of the invention that may provide certain benefits under some circumstances. It is to be appreciated, however, that other embodiments may also be preferred under the same or different circumstances. The recitation of one or more preferred embodiments therefore does not mean or imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure, or from the scope of the claims. 

1. An aerosol-forming article comprising an aerosol-forming substrate and a terminal filter element at a downstream axial end of the article/consumable wherein the terminal filter element comprises a hollow bore extending from an upstream axial end of the terminal filter element to a downstream axial end of the terminal filter element wherein the hollow bore is off-set from the axial centre of the terminal filter element.
 2. An article according to claim 1, wherein the aerosol-forming article is a heat-not-burn (HNB) consumable.
 3. An article according to claim 1, further comprising an upstream filter element provided upstream of the terminal filter element.
 4. An article according to claim 3 wherein the upstream filter element is a hollow bore filter element comprising an axial bore.
 5. An article according to claim 3, wherein the diameter of the axial bore in the upstream filter element is greater than the diameter of the offset bore in the terminal filter element.
 6. An article according to claim 3, wherein the porosity of the upstream filter element is less than the porosity of the terminal filter element.
 7. An article according to claim 3, wherein the upstream and terminal filter elements are spaced apart by a cooing element and/or a spacer element.
 8. A system comprising: a smoking substitute article having a downstream axial end, the smoking substitute article comprising: an aerosol-forming substrate; and a terminal filter element having an upstream axial end and a downstream axial end, and a hollow bore extending from the upstream axial end of the terminal filter element to the downstream axial end of the terminal filter element, wherein the hollow bore is off-set from an axial centre of the terminal filter element; and a device comprising a heating element.
 9. A system according to claim 8, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 10. A method of using the system according to claim 8, the method comprising: inserting the article into the device; and heating the article using the heating element.
 11. A method according to claim 10, comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 12. A Heat-Not-Burn (HNB) consumable comprising an aerosol-forming substrate and a flow restrictor element downstream of the aerosol-forming substrate.
 13. A HNB consumable according to claim 12, further comprising in axial flow arrangement, an upstream filter element, a spacer element, and a terminal filter element, wherein at least one of the filter elements is a hollow bore filter element and wherein the flow restrictor element is provided upstream of the terminal filter element and downstream of the aerosol-forming substrate.
 14. An aerosol-forming article comprising, in axial flow arrangement, an aerosol-forming substrate, an upstream filter element, a spacer element and a terminal filter element, wherein at least one of the filter elements is a hollow bore filter element and wherein the article further comprises a flow restrictor element upstream of the terminal filter element and downstream of the aerosol-forming substrate.
 15. A consumable/article according to claim 14 wherein the flow restrictor element comprises a disc or rod having at least one axial perforation or channel.
 16. A consumable/article according to claim 15 wherein the flow restrictor element has a single perforation or channel at its axial centre having a diameter of between 0.5 and 1.5 mm.
 17. A consumable/article according to claim 14 wherein the flow restrictor element is formed of a vapour-impermeable material.
 18. A consumable/article according to claim 14 wherein the flow restrictor element is formed of extruded tobacco.
 19. A consumable/article according to claim 14 wherein the flow restrictor element is provided upstream of the spacer element.
 20. A consumable/article according to claim 19 wherein the restrictor element is interposed between the upstream filter element and the spacer element.
 21. A consumable/article according to claim 14 wherein the upstream filter element is a hollow bore filter having a bore diameter greater than 1.5 mm.
 22. A consumable/article according to claim 14 wherein both the upstream and terminal filter element are hollow bore filter elements.
 23. A system comprising: a HNB consumable or smoking substitute article comprising, in axial flow arrangement: an aerosol-forming substrate, a flow restrictor element downstream of the aerosol-forming substrate; an upstream filter element, a spacer element; and a terminal filter element downstream of the flow restrictor element and downstream of the aerosol-forming substrate, wherein at least one of the upstream filter element and the terminal filter element is a hollow bore filter element; and a device comprising a heating element.
 24. A system according to claim 23 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 25. A method of using the system according to claim 23, the method comprising: inserting the consumable/article into the device; and heating the consumable/article using the heating element.
 26. A method according to claim 25, further comprising inserting the consumable/article into a cavity within a main body of the device and penetrating the consumable/article with the heating element upon insertion of the consumable/article.
 27. An aerosol-forming article comprising a cooling element comprising a phase change material.
 28. An article according to claim 27, wherein the article is a heat not burn (HNB) consumable.
 29. An article according to claim 27, wherein the phase change material is an organic phase change material.
 30. An article according to claim 29, wherein the phase change material is eicosane.
 31. An article according to claim 27, wherein the cooling element comprises a plurality of phase change beads each comprising a shell enclosing a core formed of the phase change material.
 32. An article according to claim 27, wherein the cooling element comprises a cylindrical body and the phase change material/beads are dispersed within the body.
 33. An article according to claim 32, wherein the cylindrical body comprises an axial bore extending therethrough.
 34. An article according to claim 32, wherein the cylindrical body comprises a matrix of fibrous, granular, sheet or solid plastics material.
 35. An article according to claim 34, wherein the plastics material comprises one or more of viscose, cellulose, polyester, polyacrylonitrile, polylactic acid, polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), and polyethylene terephthalate (PET).
 36. An article according to claim 35, wherein the fibrous plastics material is selected from viscose, cellulose, polyester, acrylic or polylactic acid fibres.
 37. An article according to claim 27, wherein the cooling element is formed of Outlast® viscose fibres.
 38. An article according to claim 27, wherein the cooling element is sandwiched between a terminal filter element and an upstream filter element downstream of an aerosol-forming substrate.
 39. A system comprising a smoking substitute article according to claim 27 and a device comprising a heating element.
 40. A system according to claim 39, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 41. A method of using the system according to claim 39, the method comprising: inserting the article into the device; and heating the article using the heating element.
 42. A method according to claim 41, comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 43. An aerosol-forming article comprising an aerosol-forming substrate wherein the article further comprises: a terminal filter element at the axial downstream of end of the article, the terminal filter element being a hollow bore filter element; and one or more of an upstream filter element, an upstream aerosol-cooling element and an upstream spacer element.
 44. An article according to claim 43, wherein the internal diameter of the bore in the terminal filter element is between 1 and 3 mm.
 45. An article according to claim 43, comprising the upstream filter element wherein the upstream filter element is a hollow bore filter element.
 46. An article according to claim 45, wherein the internal diameter of the bore in the upstream filter element is greater than the internal diameter of the bore in the terminal filter element.
 47. An article according to claim 45, wherein the density of the filter material forming the terminal filter element is greater than the density of the filter material forming the upstream filter element.
 48. An article according to claim 45, wherein the upstream filter element and terminal filter element are axially spaced.
 49. An article according to claim 48, further comprising the aerosol-cooling element wherein the upstream filter element and terminal filter element are spaced by the aerosol-cooling element.
 50. An article according to claim 48, further comprising the spacer element wherein the upstream filter element and terminal filter element are spaced by the spacer element.
 51. An article according to claim 45, wherein the spacer element is a cardboard tube.
 52. An article according to claim 45, wherein the aerosol-cooling element comprises a crimped/gathered sheet of plastics material.
 53. A system comprising a smoking substitute article according to claim 45, and a device comprising a heating element.
 54. A system according to claim 53, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 55. A method of using the system according to claim 53, the method comprising: inserting the article into the device; and heating the article using the heating element.
 56. A method according to claim 55, comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 57. An aerosol-forming article comprising an aerosol-forming substrate wherein the aerosol-forming substrate comprises a first, upstream portion of aerosol-forming material and a second, downstream portion of aerosol-forming material wherein the first and second portions of aerosol-forming material are axially spaced by a cavity housing a vapour modifier.
 58. An aerosol-forming article according to claim 57 wherein the first portion of aerosol-forming material and the second portion of aerosol-forming material are both formed of a first aerosol-forming material.
 59. An aerosol-forming article according to claim 58 wherein the vapour modifier comprises a second aerosol-forming material.
 60. An aerosol-forming article according to claim 059 wherein the second aerosol-forming material is extruded tobacco.
 61. An aerosol-forming article according to claim 60 wherein the second aerosol-forming material is extruded tobacco chips/pellets/granules.
 62. An aerosol-forming article according to any one of claims 58 to 61 wherein the first aerosol-forming material comprises one or more of tobacco, tobacco derivatives, expanded tobacco, shredded tobacco and/or reconstituted tobacco.
 63. An aerosol-forming article according to any one of the preceding claims wherein the vapour modifier is an additive carrier.
 64. An aerosol-forming article according to claim 063 wherein the additive carrier is a crushable or meltable capsule.
 65. An aerosol-forming article according to claim 063 or 64 wherein the additive carrier contains a humectant or a flavourant.
 66. A smoking substitute system comprising an article according to any one of the preceding claims and a device comprising a heating element.
 67. A system according to claim 066 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 68. A method of using the system according to claim 066 or 67, the method comprising: inserting the article into the device; and heating the article using the heating element.
 69. A method according to claim 068 comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 70. A filter element for an aerosol-forming article, the filter element comprising a bundle of filter tows with a bore extending longitudinally therethrough, at least a portion of the bore having a non-circular transverse cross-section.
 71. A filter element according to claim 70, wherein the transverse cross-section of the at least a portion of the bore comprises a central portion and a plurality of lobes projecting outwardly from the central portion.
 72. A filter element according to claim 70, wherein the transverse cross-section of at least a portion of the bore is any one of a square, triangle, heart shape, star shape or asterisk shape.
 73. A filter element according to claim 70, wherein the transverse cross-sectional area of the bore is substantially uniform for the entire axial length of the bore.
 74. A filter element according to claim 70, wherein the shape of the transverse cross-section of the bore is substantially uniform for the entire length of the bore.
 75. A filter element according to claim 70, comprising a plurality of bores, at least a portion of each of the plurality of bores having a non-circular transverse cross-section.
 76. An aerosol-forming article comprising an aerosol-forming substrate and a filter element according to claim 70, downstream of the aerosol-forming substrate.
 77. An aerosol-forming article according to claim 76, wherein the filter element is a terminal filter element located at a downstream axial end of the aerosol-forming article.
 78. An aerosol-forming article according to claim 76, that is a heat-not-burn (HNB) consumable.
 79. A system comprising an aerosol-forming article according to claim 70, and a device comprising a heating element.
 80. A system according to claim 79, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 81. A method of using the system according to claim 79, the method comprising: inserting the article into the device; and heating the article using the heating element.
 82. A method according to claim 81, comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 83. An aerosol-forming article comprising an aerosol-forming substrate wherein the aerosol-forming substrate comprises at least a first aerosol-forming material and a second aerosol forming material wherein the first and second aerosol-forming materials are axially and/or radially segregated within the aerosol-forming substrate.
 84. An aerosol-forming article according to claim 83, wherein the aerosol-forming materials are axially segregated and the aerosol-forming substrate comprises at least a first rod- or tube-shaped portion and a second rod- or tube-shaped portion.
 85. An aerosol-forming article according to claim 84, wherein the first and second rod/tube portions are axially adjacent one another within the substrate.
 86. An aerosol-forming article according to claim 83, wherein the aerosol-forming materials are radially segregated and the aerosol-forming substrate comprises at least a first, radially outer rod- or tube-shaped portion (formed of the first aerosol-forming material) and a second, radially inner tube-shaped portion (formed of the second aerosol-forming material).
 87. An aerosol-forming article according to claim 86, wherein the first and second rod/tube portions are radially adjacent one another.
 88. An aerosol-forming article according to claim 83, wherein one of the first and second aerosol-forming materials comprises extruded tobacco.
 89. An aerosol-forming article according to claim 88, wherein the extruded tobacco is in the form of a rod- or tube-shaped extrudate or chips/granules/pellets.
 90. A smoking substitute article according to claim 83, wherein one of the first and second aerosol-forming materials comprises reconstituted tobacco and the other comprises extruded tobacco.
 91. A smoking substitute system comprising an article according to claim 83, and a device comprising at least one heating element.
 92. A system according to claim 91, wherein the device comprises a first heating element for heating the first aerosol-forming material within the substrate and a second heating element for heating the second aerosol forming material.
 93. A system according to claim 92, wherein the first and second heating elements are separately controllable.
 94. A method of using the system according to claim 91, the method comprising: inserting the article into the device; and heating the article using the heating element(s).
 95. A method according to claim 94, comprising heating the first aerosol-forming material in the aerosol-forming substrate using a the first heating element and heating the second aerosol-forming material in the aerosol-forming substrate using the second heating element.
 96. A method according to claim 95, comprising heating the first aerosol-forming material at a different rate and/or temperature than the second aerosol-forming material.
 97. An aerosol-forming article comprising an aerosol-forming substrate and a terminal filter element, wherein the terminal filter element comprises an upstream filter portion and an axially adjacent downstream filter portion, and wherein one of the upstream and downstream filter portions is a hollow bore filter element and the other is a solid filter element.
 98. An aerosol-forming article according to claim 97, wherein the upstream filter portion is the solid filter element, and the downstream filter portion is the hollow bore filter element.
 99. An aerosol-forming article according to claim 97, wherein the terminal filter element has an axial length of between 11 mm and 13 mm.
 100. An aerosol-forming article according to claim 97, wherein the upstream filter portion and the downstream filter portion have substantially the same axial length.
 101. An aerosol-forming article according to claim 100, wherein the axial length of each of the upstream and downstream filter portions is around 6 mm.
 102. An aerosol-forming article according to claim 97, wherein the upstream and downstream filter portions are joined by way of a plug wrap at least partly circumscribing the upstream and downstream filter portions.
 103. An aerosol-forming article according to claim 97, wherein the filter portion that is the solid filter element comprises a flavourant.
 104. An aerosol-forming article according to claim 97, further comprising a hollow bore upstream filter element located between the aerosol-forming substrate and the terminal filter element.
 105. An aerosol-forming article according to claim 97, wherein the article is a heat not burn (HNB) consumable.
 106. A method of forming an aerosol-forming article, the method comprising: joining a first filter portion to a second filter portion to form a terminal filter element; and combining the terminal filter element with an aerosol-forming substrate to form the aerosol-forming article.
 107. A method according to claim 106, wherein the first filter portion is a hollow bore filter element and the second filter portion is a solid filter element.
 108. A method according to claim 106, wherein the first and second filter portions are joined by a plug wrap.
 109. A method according to claim 106, wherein the combined axial length of the first and second filter portions is around 12 mm and the step of combining the terminal filter element with the substrate is performed using a combining machine configured for combining terminal filter elements having an axial length of 12 mm.
 110. A system comprising a smoking substitute article according to claim 97, and a device comprising a heating element.
 111. A system according to claim 110, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 112. A method of using the system according to claim 110, the method comprising: inserting the article into the device; and heating the article using the heating element.
 113. A method according to claim 112 comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 114. An aerosol-forming article comprising an aerosol-forming substrate at least partly comprising a rod of extruded plant material wherein the article further comprises a terminal filter element at the downstream axial end and an upstream filter element upstream and axially spaced from the terminal filter element.
 115. An article according to claim 114, wherein the article is a heat not burn (HNB) consumable.
 116. An article according to claim 114, wherein the rod of extruded plant material has an axial bore adapted to receive an external heating element.
 117. An article according to claim 114, wherein the aerosol-forming substrate comprises a rod of extruded tobacco.
 118. An article according to claim 114, wherein the aerosol-forming substrate further comprises one or more additives selected from humectants, fillers, solvents, flavourants, and binders.
 119. An article according to claim 114, wherein the upstream filter element and terminal filter element are axially spaced by a cooling element or a spacer.
 120. An article according to claim 114, wherein the upstream filter element is axially adjacent the aerosol-forming substrate.
 121. An article according to claim 114, wherein the filter element and/or the terminal filter element is/are a hollow bore element.
 122. An article according to claim 121, wherein both the upstream and terminal filer elements are hollow bore filter elements.
 123. A smoking substitute system comprising an article according to an claim 114, and a device comprising a heating element.
 124. A system according to claim 123, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 125. A method of using the system according to claim 123, the method comprising: inserting the article into the device; and heating the article using the heating element.
 126. A heat not burn consumable comprising an aerosol-forming substrate and a terminal filter element, wherein the axial length of the terminal filter element is adjustable.
 127. A consumable according to claim 126, wherein the terminal filter element comprises a plurality of filter portions in axial abutment with one another and wherein one or more of the filter portions is/are removable from the consumable to adjust the axial length of the terminal filter element.
 128. A consumable according to claim 126, wherein the terminal filter element comprises a hollow bore filter portion.
 129. A consumable according to claim 128, wherein the hollow bore filter portion is upstream from the downstream axial end of the consumable.
 130. A consumable according to claim 129, further comprising a solid filter portion at the axial downstream end of the consumable.
 131. A consumable according to claim 127, wherein the terminal filter element is circumscribed by a tipping paper and wherein the tipping paper comprises a region of weakness aligned with a join between two filter portions.
 132. A consumable according to claim 131, wherein the region of weakness comprises an array of perforations in the tipping paper.
 133. An aerosol-forming article comprising an aerosol-forming substrate and a terminal filter element wherein the axial length of the terminal filter element is adjustable and wherein the terminal filter element comprises a hollow bore filter portion and a solid filter portion.
 134. An article according to claim 133, wherein the terminal filter element is circumscribed by a tipping paper and wherein the tipping paper comprises a region of weakness aligned with a join between the two filter portions.
 135. An article according to claim 134, wherein the region of weakness comprises an array of perforations in the tipping paper.
 136. A system comprising a consumable or an article according to claim 126, and a device comprising a heating element.
 137. A system according to claim 136, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 138. A method of using the system according to claim 136, the method comprising: inserting the consumable/article into the device; and heating the consumable/article using the heating element.
 139. A method according to claim 135, comprising inserting the consumable/article into a cavity within a main body of the device and penetrating the consumable/article with the heating element upon insertion of the consumable.
 140. A method according to claim 135, comprising reducing the axial length of the terminal filter element.
 141. An aerosol-forming article comprising an aerosol-forming substrate and a plurality of filter elements having different axial lengths.
 142. An article according to claim 141, wherein the article is a heat-not-burn (HNB) consumable.
 143. An article according to claim 141, comprising a terminal filter element at the downstream/mouth end of the article and an upstream filter element upstream of the terminal filter element.
 144. An article according to claim 143, wherein the axial length of the terminal filter element is greater than the axial length of the upstream filter element.
 145. An article according to claim 143, wherein the axial length of the terminal filter element is 2 mm or more greater than the axial length of the upstream filter element.
 146. An article according to claim 143, wherein the terminal filter element is a hollow bore filter element.
 147. An article according to claim 146, wherein the upstream filter element is a hollow bore filter element.
 148. An article according to claim 147, wherein the terminal filter element has an axial bore having a smaller diameter than an axial bore in the upstream filter element.
 149. An article according to claim 143, wherein the upstream filter element has a greater porosity than the terminal filter element.
 150. An article according to claim 143, wherein the upstream filter element and terminal filter element are spaced by an aerosol-cooling element and/or a spacer element.
 151. A system comprising a smoking substitute article according to claim 143, and a device comprising a heating element.
 152. A system according to claim 151, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 153. A method of using the system according to claim 151, the method comprising: inserting the article into the device; and heating the article using the heating element.
 154. A method according to claim 153, comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 155. An aerosol-forming article comprising an aerosol-forming substrate and a plurality of hollow bore filter elements having different internal bore diameters.
 156. An article according to claim 155, wherein the article is a heat-not-burn (HNB) consumable.
 157. An article according to claim 155, comprising a terminal hollow bore filter element at the downstream/mouth end of the article and an upstream hollow bore filter element upstream of the terminal filter element.
 158. An article according to claim 157, wherein the terminal hollow bore filter element has an axial bore having a smaller diameter than an axial bore in the upstream hollow bore filter element.
 159. An article according to claim 158, wherein the diameter of the axial bore in the upstream hollow bore filter element is at least 1 mm greater than the diameter of the axial bore in the terminal filter element.
 160. An article according to claim 157, wherein the axial length of the terminal hollow bore filter element is greater than the axial length of the upstream hollow bore filter element.
 161. An article according to claim 160, wherein the axial length of the terminal hollow bore filter element is 2 mm or more greater than the axial length of the upstream hollow bore filter element.
 162. An article according to claim 157, wherein the upstream hollow bore filter element has a greater porosity than the terminal hollow bore filter element.
 163. An article according to claim 157, wherein the upstream hollow bore filter element and terminal hollow bore filter element are spaced by an aerosol-cooling element and/or a spacer element.
 164. A system comprising a smoking substitute article according to claim 157, and a device comprising a heating element.
 165. A system according to claim 164, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 166. A system according to claim 164, comprising a rod-shaped heater having an external diameter wherein the internal diameter of the bore of the upstream hollow bore filter element is greater than the external diameter of the rod-shaped heater.
 167. A method of using the system according to claim 164, the method comprising: inserting the article into the device; and heating the article using the heating element.
 168. A method according to claim 167, comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 169. An aerosol-forming article comprising an aerosol-forming substrate and a plurality of filter elements wherein at least two of the filter elements have different hardness from one another.
 170. An article according to claim 169, wherein the article is a heat-not-burn (HNB) consumable.
 171. An article according to claim 169, comprising a terminal filter element at the downstream/mouth end of the article and an upstream filter element upstream of the terminal filter element.
 172. An article according to claim 171, wherein the hardness of the terminal filter element is greater than the hardness of the upstream filter element.
 173. An article according to claim 172, wherein the hardness of the terminal filter element is at least 3% greater than the hardness of the upstream filter element.
 174. An article according to claim 171, wherein the axial length of the terminal filter element is greater than the axial length of the upstream filter element.
 175. An article according to claim 174, wherein the axial length of the terminal filter element is 2 mm or more greater than the axial length of the upstream filter element.
 176. An article according to claim 171, wherein the terminal filter element is a hollow bore filter element.
 177. An article according to claim 176, wherein the upstream filter element is a hollow bore filter element.
 178. An article according to claim 177, wherein the terminal filter element has an axial bore having a smaller diameter than an axial bore in the upstream filter element.
 179. An article according to claim 171, wherein the upstream filter element and terminal filter element are spaced by an aerosol-cooling element and/or a spacer element.
 180. A system comprising a smoking substitute article according to claim 171, and a device comprising a heating element.
 181. A system according to claim 180, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 182. A method of using the system according to claim 180, the method comprising: inserting the article into the device; and heating the article using the heating element.
 183. A method according to claim 181, comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 184. An aerosol-forming article comprising an aerosol-forming substrate and a hollow bore terminal filter element at a downstream axial end of the article/consumable wherein the article comprises at least one radial air flow path into the aerosol-forming substrate.
 185. An article according to claim 184, wherein the article is a heat-not-burn (HNB) consumable.
 186. An article according to claim 184, comprising a plurality of radial air flow paths which may be circumferentially-arranged around the aerosol-forming article.
 187. An article according to claim 184, wherein the aerosol-forming substrate is circumscribed by a wrapping layer and the radial air flow path(s) may be provided by one or more ventilation holes provided in the wrapping layer.
 188. An article according to claim 184, further comprising a spacer element or an aerosol-cooling element upstream and axially adjacent the terminal filter element.
 189. An article according to claim 184, further comprising an upstream filter element provided upstream of terminal filter element and downstream of the aerosol-forming substrate.
 190. An article according to claim 189 wherein the upstream filter element is a hollow bore filter element.
 191. An article according to claim 184, wherein the aerosol-forming substrate comprises a gathered sheet of homogenised tobacco or gathered shreds/strips formed from such a sheet.
 192. An article according to claim 184, wherein the aerosol-forming substrate further comprises one or more additives selected from humectants, flavourants, fillers, aqueous/non-aqueous solvents and binders.
 193. A system comprising a smoking substitute article according to claim 184, and a device comprising a heating element.
 194. A system according to claim 193, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 195. A method of using the system according to claim 193, the method comprising: inserting the article into the device; and heating the article using the heating element.
 196. A method according to claim 195, comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 197. An aerosol-forming article comprising an aerosol-forming substrate and a terminal filter element at the downstream axial end of the article wherein the terminal filter element comprises an adsorbent additive.
 198. An article according to claim 197, wherein the adsorbent additive is selected from one or more of a zeolite, an activated carbon, a silica gel, a clay, a porous polymer and activated alumina.
 199. An article according to claim 198, wherein the adsorbent is activated carbon.
 200. An article according to claim 197, wherein the terminal filter element comprises a terminal filter portion and an upstream filter portion and wherein at least a portion of adsorbent additive is sandwiched between the upstream filter portion and the terminal filter portion.
 201. An article according to claim 197, wherein the adsorbent additive is evenly distributed throughout the terminal filter portion.
 202. An article according to claim 197, further comprising an upstream filter element.
 203. An article according to claim 202, wherein the terminal filter element and the upstream filter element are axially spaced by an aerosol-cooling element and/or a spacer element.
 204. An aerosol-forming article comprising an aerosol-forming substrate and at least one filter element wherein the at least one filter element comprises at least one polar solvent.
 205. An aerosol-forming article according to claim 204, wherein the at least one polar solvent is one or more polar solvents selected from water and polar organic solvents.
 206. An aerosol-forming article according to claim 205, wherein the polar organic solvent(s) is/are selected from ethanol, isopropyl alcohol and dimethylsulfoxide.
 207. An aerosol-forming article according to claim 204, wherein the at least one polar solvent is evenly distributed throughout the filter element.
 208. An aerosol-forming article according to claim 204, wherein the at least one polar solvent is concentrated in discrete regions within the filter element.
 209. An aerosol-forming article according to claim 208, wherein the polar solvent is contained in one or more frangible capsules.
 210. An aerosol-forming article according to claim 209, wherein the or each capsule is a crushable capsule configured to break and release the polar solvent when crushed.
 211. An aerosol-forming article according to claim 209, wherein the or each capsule is a thermally labile capsule configured to melt/deform and release the polar solvent when heated.
 212. An aerosol-forming article according to claim 204, wherein the filter element is a terminal filter element.
 213. A method comprising: using a polar solvent in a filter element of an aerosol-forming article to filter hazardous substances from an aerosol that is drawn through the filter element.
 214. The method according to claim 213, wherein the aerosol forming article comprises an aerosol-forming substrate and at least one filter element wherein the at least one filter element comprises at least one polar solvent.
 215. An article according to claim 197, wherein the article is a heat not burn (HNB) consumable.
 216. A system comprising an article according to claim 197 a device comprising a heating element.
 217. A system according to claim 216 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 218. A method of using the system according to claim 216, the method comprising: inserting the article into the device; and heating the article using the heating element.
 219. A method according to claim 218, comprising inserting the article into a cavity within a main body of the device main body and penetrating the article with the heating element upon insertion of the article.
 220. An aerosol-forming article comprising an aerosol-forming substrate and at least one filter element downstream of the substrate wherein the at least one filter element is a hollow bore filter element and wherein the article has at least one unimpeded flow path along the outer surface of the filter element.
 221. An article according to claim 220 wherein the article is a heat-not-burn (HNB) consumable.
 222. A heat-not-burn (HNB) consumable comprising an aerosol-forming substrate and at least one filter element downstream of the substrate wherein the consumable has at least one unimpeded flow path along the outer surface of the filter element.
 223. The consumable of claim 222 wherein the filter element is a solid filter element.
 224. The consumable of claim 222, wherein the filter element has an outer surface comprising a plurality of longitudinally-extending channels.
 225. The consumable of claim 222, further comprising a sleeve circumscribing the filter element.
 226. The consumable of claim 222, wherein the filter element comprises a flavourant.
 227. The consumable according to claim 226, wherein the filter element comprises a longitudinally-extending thread carrying the flavourant.
 228. The consumable of claim 222, wherein the filter element is a terminal filter element provided at the downstream axial end of the article/consumable.
 229. The consumable according to claim 228, further comprising an upstream filter element upstream from the terminal filter element.
 230. The consumable according to claim 229, wherein the terminal filter element and the upstream filter element are axially spaced by an aerosol-cooling element and/or a spacer element.
 231. A system comprising the consumable according to claim 222, and a device comprising a heating element.
 232. A system according to claim 231, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 233. A method of using the system according to claim 231, the method comprising: inserting the consumable into the device; and heating the consumable using the heating element.
 234. A method according to claim 233, comprising inserting the consumable into a cavity within a main body of the device and penetrating the consumable with the heating element upon insertion of the consumable. 